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: An assembly includes a valve integration unit attached to a transmission oil heater. The valve integration unit includes a valve mechanism and a housing having first to sixth fluid ports for oil input and output. The interior space of the housing has a valve chamber to receive a thermal valve mechanism has a temperature responsive actuator. A bypass flow passage is located outside the heat exchanger and is in fluid communication with oil inlet and outlet manifolds through first and second bypass holes provided in the heat exchanger.

Abstract: A heat exchanger includes first and second plates between which a fluid flow passage is defined, through-holes defining inlet and outlet ports, and through fittings having first and second segments. Each segment includes a tube portion extending through one of the holes and a flange portion located inside the fluid flow passage. The flange portion of each segment has opposed first and second surfaces, the first surface joined to the inner surface of one of the plates in a fluid-tight manner. The second surfaces of both segments face each other, and at least second surface has one or more channels providing fluid flow from the hollow interior to the fluid flow passage. The second surfaces of the segments are in contact or closely apart from one another, the flange portions of the first and second segments providing support for the first and second plates in the area surrounding the ports.

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 and includes a portion that extends outwardly beyond the footprint of the heat exchanger. The adapter module is comprised of a first embossed plate that is sealed with a second plate, which may also be embossed. The embossments provide fluid transfer channels and also perform as structural ribs to enhance the rigidity of the adapter module.

Abstract: A heat exchanger assembly includes first and second heat exchangers integrated with a thermally actuated control valve assembly having first and second surfaces to which the first and heat exchangers are attached at various orientations to each other, including at 90 and 180 degrees to each other, and side-by-side. The valve assembly has two fluid ports for connection to an external fluid source, and two fluid ports in fluid communication with inlet and outlet manifolds of each heat exchanger. The heat exchangers may be a transmission oil heater and a transmission oil cooler, and the valve assembly controls the flow of transmission oil to the heat exchangers depending on the oil temperature. One or both of the heat exchangers may be brazed or mechanically secured to the valve assembly. The housing of valve assembly may be segmented, with each heat exchanger being brazed to one of the segments.

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 vehicle heating/cooling system has first and second fluid circulation loops for circulating engine coolant and automotive fluid. A first heat exchanger transfers heat from the coolant to air for the passenger compartment. A second heat exchanger transfers heat between the coolant and automotive fluid. A first valve has first and second inlets for receiving coolant from hot and cold coolant sources, and an outlet for discharging coolant to the second heat exchanger. A second valve has an inlet for receiving coolant from the first coolant source, and an outlet for discharging coolant to the first inlet of the first valve. The valve positions change with temperature of the coolant and the automotive fluid, providing preferential heating of the passenger compartment during cold start-up of the vehicle. The second heat exchanger and valves may be provided in a temperature control module.

Abstract: A battery cell heat exchanger having a pair of plates that together define a fluid passage having a first channel permitting fluid flow from a first end of the plate pair towards a second end of the plate pair, and a second channel permitting fluid flow from the second end towards the first end of the plate pair. The plate pair together defining a first conduit at the first end of the plate pair, the first conduit being in fluid communication with the first channel. One of the pair of plates having an aperture permitting fluid flow from the second channel to a duct, the duct coupled to the one of the pair of plates having the aperture and having a second conduit in fluid communication with the aperture; where the first conduit and the second conduit lie in the plane defined by the pair of plates.

Abstract: A heat exchanger with a multi-zone heat transfer surface is disclosed. The heat exchanger includes a fluid flow passage extending between and interconnecting a fluid inlet and a fluid outlet. A heat transfer surface is disposed within the fluid flow passage wherein the heat transfer surface includes at least one heat transfer-reducing zone disposed in thermal contact with a portion of at least one of the walls of the fluid flow passage and at least one heat transfer-augmenting zone disposed in thermal contact with a portion of the at least one of the walls of the fluid flow passage. The configuration of the heat transfer-augmenting zones with the heat-transfer-reducing zones is such that heat transfer across the surface of the heat exchanger in contact with the heat transfer-augmenting zones is increased relative to the heat transfer across the surface of the heat exchanger in contact with the heat transfer-reducing zones.

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 and battery unit structure is provided for cooling battery units (or cells) where the thermally conductive nature of the battery forms a cooling path. The heat exchanger is in the form of a cooling element provided with an engaging device formed on or attached to an outer surface of the cooling plate for receiving a battery unit (or cell). The interconnection between the battery unit (or cell) and heat exchanger creates a mechanical interlock between the two components that results in improved heat transfer properties between the two components.

Abstract: An integrated gas management device (GMD) for a fuel cell has a gas-to-gas humidifier for transferring water from a second gas to a first gas; and a heat exchanger attached to a first end of the humidifier core for cooling the first gas. The GMD may optionally have a thermal isolation plate between the heat exchanger and the first end of the humidifier core. The GMD further has a bypass line to allow the first gas to bypass the humidifier. The first gas may be cathode charge air and the second gas may be cathode exhaust.

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: A stacked-plate heat exchanger for cooling a plurality of heat-generating electronic components arranged in a plurality of layers comprises a stack of flat tubes defining a plurality of parallel fluid flow passages, the tubes being separated by spaces for receiving the electronic components. One or more flow-restricting ribs is arranged within at least some of the fluid flow passages to partially block fluid flow between at least one the manifolds and the heat transfer area by reducing the height of the fluid flow passage outside the heat transfer area, along at least a portion of the width of the fluid flow passage, in order to improve the flow distribution of a heat transfer fluid between and within the fluid flow passages of the heat exchanger, and to minimize bypass flow at the outer edges of the fluid flow passage.

Abstract: A heat exchanger for use with at least two battery modules, each of the battery modules comprising at least one battery cell housed within a rigid container, the heat exchanger defining an internal fluid passage for a heat exchanger fluid and having at least one compliant region that is configured to be compressed to facilitate thermal contact between the heat exchanger and the two battery modules.

Abstract: A heat exchanger for use with at least two battery modules, each of the battery modules comprising at least one battery cell housed within a rigid container, the heat exchanger defining an internal fluid passage for a heat exchanger fluid and having at least one compliant region that is configured to be compressed to facilitate thermal contact between the heat exchanger and the two battery modules.

Abstract: An assembly includes a valve integration unit attached to a transmission oil heater. The valve integration unit includes a valve mechanism and a housing having first to sixth fluid ports for oil input and output. The interior space of the housing has three portions, including a second portion defining a valve chamber and a third portion defining a bypass flow passage between the first and second portions. The valve mechanism has a temperature responsive actuator and first, second and third valve members. The movement of the first and second valve members is actuated by the temperature responsive actuator. The third valve member and the third valve opening are located in the second portion of the interior space. The third valve member is actuatable in response to a pressure differential between the first and second portions of the interior space.

Abstract: Various ways to integrate control valves into the structure of a heat exchanger are disclosed. 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 the fluid passage.

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 device and method for alignment of parts for welding, having a bottom welding fixture and a top welding fixture. The bottom welding fixture has a plurality of fixed locating pins for positioning of parts to be welded and limiting movement of the parts in a first axis and a perpendicular second axis. At least pair of alignment block assemblies to actuate movement of the parts to be welded in the first and second axes. The alignment block assembly having an alignment block moveable from a first position to a second position for contacting and aligning the parts. An actuator coupled to the top welding or bottom welding fixture to actuate movement of the alignment block from the first position to the second position upon engagement of the top welding fixture to the bottom welding fixture.