Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A heat exchanger for cooling multiple rows of battery cells has a plurality of longitudinal flow sections defining at least first and second U-shaped flow areas, each underlying a row of battery cells. The flow sections includes inlet and outlet flow sections, and at least two intermediate flow sections. Inlet and outlet ports are in flow communication with the respective inlet and outlet flow sections, and a first bypass channel extends between the inlet port and at least one of the intermediate flow sections. The first bypass channel supplies relatively cold heat transfer fluid from the inlet to mix with warmer fluid in a second or subsequent U-shaped flow area, to improve temperature uniformity between the rows of battery cells. A second bypass channel may extend around the outer periphery of the heat exchanger, from the inlet flow section to a second or subsequent U-shaped flow area.

Abstract: A heat exchanger has a pair of opposed walls and an interior space between the walls, and first and second areas located on opposite sides of a longitudinal axis, each adapted for thermal contact with a battery cell. Inlet and outlet ports are provided in the respective first and second areas, and a flow barrier extends along the longitudinal axis and separates the first and second areas. Fluid flow passages are defined in the first and second areas. A first crossover passage extends across the longitudinal axis from the inlet port to an inlet flow passage in the second area. A second crossover passage extends across the longitudinal axis from an outlet flow passage in the first area to the outlet port. A crossover housing is provided inside or outside the interior space and extends across the longitudinal axis, enclosing at least one of the first and second crossover passages.

Abstract: A heat exchanger has a fluid flow passage defined between first and second plates, and at least one through fitting having a one-piece construction. The through fitting has a first portion extending through a first hole of the first plate, a second portion extending a second hole of the second plate, and a radially outwardly extending third portion located between the first and second plates. The third portion of the through fitting has a first radially-extending surface in contact with the inner surface of the first plate and a second radially-extending surface in contact with the inner surface of the second plate. At least one communication passage is provided through the third portion of the through fitting between the fluid flow passage and the hollow interior of the through fitting. A plurality of the heat exchangers may be fluidly connected in parallel flow arrangement.

Abstract: A heat exchanger has a pair of opposed walls and an interior space between the walls, and first and second areas located on opposite sides of a longitudinal axis, each adapted for thermal contact with a battery cell. Inlet and outlet ports are provided in the respective first and second areas, and a flow barrier extends along the longitudinal axis and separates the first and second areas. Fluid flow passages are defined in the first and second areas. A first crossover passage extends across the longitudinal axis from the inlet port to an inlet flow passage in the second area. A second crossover passage extends across the longitudinal axis from an outlet flow passage in the first area to the outlet port. A crossover housing is provided inside or outside the interior space and extends across the longitudinal axis, enclosing at least one of the first and second crossover passages.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A heat exchanger for cooling multiple rows of battery cells has a plurality of longitudinal flow sections defining at least first and second U-shaped flow areas, each underlying a row of battery cells. The flow sections includes inlet and outlet flow sections, and at least two intermediate flow sections. Inlet and outlet ports are in flow communication with the respective inlet and outlet flow sections, and a first bypass channel extends between the inlet port and at least one of the intermediate flow sections. The first bypass channel supplies relatively cold heat transfer fluid from the inlet to mix with warmer fluid in a second or subsequent U-shaped flow area, to improve temperature uniformity between the rows of battery cells. A second bypass channel may extend around the outer periphery of the heat exchanger, from the inlet flow section to a second or subsequent U-shaped flow area.