Abstract: A heat exchanger having a stack of nested shells joined to a base plate includes two coolant manifolds and four fluid manifolds extending through the stack. The coolant manifolds extend the entire length of the stack in the stacking direction. Two of the fluid manifolds extend from one end of the stack to an intermediate location along the stacking direction, and the other two fluid manifolds extend from the other end of the stack to the intermediate location. Fluid transfer conduits extend through the stack, from a face of the base plate opposite the stack to the fluid manifolds at the end of the stack opposite the base plate, in order to transfer fluid to and from fluid flow passages extending between those fluid manifolds at that end of the stack.

Abstract: A method of making a heat exchanger that includes sealing tubes to header slots and brazing the tubes to the header slots. The method further includes coupling a cover to the header to cover a liquid-side surface of the header and to cover ends of the tubes, and applying flux to an air-side surface of the header and to the tubes. Coupling the cover to the header is performed after sealing the tubes to the header slots and coupling the cover to the header is performed before applying flux to the air-side surface of the header and to the tubes. Applying flux is performed before brazing each of the tubes to the header slots and sealing each of the tubes to the header slot includes sealing a perimeter of each of the tubes to the header slot.

Abstract: Systems and methods for disrupting a flow of refrigerant within a heat exchanger assembly. One embodiment provides a method that includes receiving, with a controller, a first signal from a first sensor, the first signal indicative of a pressure of the refrigerant flowing through the heat exchanger. The method includes setting, with the controller, an operating frequency of a valve based on the first signal. The operating frequency includes a rate at which the valve actuates between a first valve position that sets a first refrigerant flow rate through the heat exchanger and a second valve position that sets a second refrigerant flow rate through the heat exchanger. The method includes controlling, with the controller, operation of a solenoid to actuate the valve at the operating frequency.

Abstract: A heat exchanger module mountable to a vehicle frame by first and second lateral sides of the heat exchanger module. The heat exchanger module includes a fan shroud. The fan shroud is a structural fan shroud. The fan shroud includes first and second frame brackets extending from the fan shroud, one on the first lateral side and one on the second lateral side. The fan shroud is attached to at least one of a first heat exchanger and a second heat exchanger by at least one fastener that extends through the fan shroud.

Abstract: A liquid to refrigerant heat exchanger includes an enclosed coolant volume that is at least partially defined by a plastic housing and by a metal closure plate. The metal closure plate can be part of a brazed assembly containing a continuous refrigerant flow path. The refrigerant flow path is disposed within the coolant volume, where heat can be transferred between the refrigerant within the refrigerant flow path and the liquid within the coolant volume. The plastic housing can at least partially surround the refrigerant flow path to at least partially bound a liquid flow path along a portion of the coolant volume. An inlet diffuser and an outlet diffuser can be mounted to the housing to direct the liquid through the housing. The plastic housing is sealingly joined to the closure plate along an outer periphery of the closure plate.

Abstract: A header for a heat exchanger includes a first and a second cylindrical fluid manifold extending in parallel. Each of the first and second manifolds have tube slots that extend through an arcuate wall section of the manifold. A thickened wall section of the header having a generally triangular wall section is bounded by the first and second fluid manifolds and by a planar outer surface of the header. An aperture extends through the thickened wall section to provide a fluid communication pathway between the first and second cylindrical fluid manifolds.

Abstract: A heat exchanger includes a housing with an inlet port, an outlet port, an interior facing surface defining a coolant channel, a first opening surrounded by an exterior facing surface, and a second opening defined by a first inner diameter. A tube assembly defines a plurality of exhaust gas flow channels and a plurality of coolant cross channels within the housing. A first diffuser directs a first fluid into the tube assembly and is joined to a first header plate, which separates the first fluid from a second fluid within the coolant channel. A second diffuser directs the first fluid out of the tube assembly. The second diffuser is located within the second opening and sealed to the second opening by seals around the second diffuser.

Abstract: A plate heat exchanger includes a stack of plate pairs with gaps between adjacent pairs, arranged to provide flow paths for a first fluid to pass through inner volumes of the plate pairs while simultaneously allowing a second fluid to flow over the outer surfaces of the plate pairs. At least one cylindrical fluid manifold for the first fluid extends through the plate pairs. A non-planar cap is arranged at one end of the plate heat exchanger to close off the cylindrical fluid manifold. A reinforcement plate is arranged at that end between the non-planar cap and an end plate of the plate heat exchanger. The position of the non-planar cap relative to a central axis of the cylindrical fluid manifold is maintained in order to prevent failure of the plate heat exchanger due to internal pressurization.

Abstract: A method of making a heat exchanger that includes sealing tubes to header slots and brazing the tubes to the header slots. The method further includes coupling a cover to the header to cover a liquid-side surface of the header and to cover ends of the tubes, and applying flux to an air-side surface of the header and to the tubes. Coupling the cover to the header is performed after sealing the tubes to the header slots and coupling the cover to the header is performed before applying flux to the air-side surface of the header and to the tubes. Applying flux is performed before brazing each of the tubes to the header slots and sealing each of the tubes to the header slot includes sealing a perimeter of each of the tubes to the header slot.

Abstract: A tube for a heat exchanger includes a tube outer body enclosing a tube inner volume, and a corrugated insert received within the tube inner volume. The tube outer body has a pair of broad planar walls joined by arcuate end walls. The corrugated insert defines flow channels through the tube, with opening in flanks of the insert allowing for flow communication between adjacent flow channels. Bypass channels adjacent the arcuate end walls are fluidly isolated from the adjacent flow channels by the absence of such openings in the end flanks. Flow through the bypass channels is obstructed by flow blocks at one or both ends of the bypass channels.

Abstract: A brazeable metal sheet material for heat exchanger components is used for producing a heat exchanger by a controlled atmosphere brazing process. The metal sheet material is made up of a core material with a brazing layer at least on one side and a corrosion-reducing intermediate layer arranged between the brazing layer and the core material. The core material consists of an Al3000-series alloy or an Al6000-series alloy having a magnesium content of 0.1% to 1.5% by weight. The brazing layer consists of an Al4000-series alloy having a maximum of 0.2% magnesium by weight. The corrosion-reducing intermediate layer consists of an Al1000-series alloy or an Al7000-series alloy having 0.1% to 1.5% magnesium by weight.

Abstract: A plate assembly for a heat exchanger includes a first plate, a second plate, and an intermediate plate arranged between the first and second plates. The intermediate plate is joined to the first and second plates at peripheral edges to create a sealed periphery of the plate assembly. Corrugations of the intermediate plate provide crests and troughs that are in contact with inwardly facing surfaces of the first and second plates. The plate assembly can be configured as a battery cooling plate heat exchanger to transfer heat from a battery to fluid flowing through the plate assembly.

Abstract: A frameless cooling module includes a first and a second shroud panel arranged at opposing sides of the module and extending from the front of the module to the back of the module. At least one L-shaped stiffener bracket extends between the panels at an intermediate location along both the height direction and the depth direction of the module. One or more heat exchangers is arranged within the cooling module between the L-shaped stiffener bracket and the front of the module, and is at least partially secured within the cooling module by being mounted to the L-shaped stiffener bracket.

Abstract: An air fin for a heat exchanger has air channels defined by corrugations, the corrugations having generally planar flanks joined by alternating crests and troughs. Perforations extend through portions of at least some of the flanks and are aligned within two spaced apart planes. A rectangular aperture extends through at least two consecutive ones of the corrugations, and is bounded by the two planes. A method of making the air fin includes forming perforations into a continuous strip of metal sheet at regular intervals, corrugating the strip to form crests and troughs between the perforations, and punching out a portion of the strip at regular intervals. The punching out includes shearing webs between the perforations, and results in the formation of the rectangular aperture.

Abstract: A heat exchanger has a turbulating insert arranged between a pair of plates. The turbulating insert is permeable to fluid flow in both a high-pressure-drop direction and a low-pressure drop direction. One portion of the turbulating insert has the high-pressure-drop direction oriented at a non-zero angle to the high-pressure-drop direction of another portion. A method of making the heat exchanger includes forming a turbulating insert, removing a portion of the turbulating insert to create a cavity within the turbulating insert, placing the remaining turbulating insert into a stamped first plate, and placing the removed portion of the turbulating insert into the cavity at a non-zero angle of rotation relative to the remaining turbulating insert.

Abstract: A tank for a heat exchanger includes an extruded tank section having a generally constant extrusion profile extending in a longitudinal direction from a first tank end to a second tank end. A first planar end cap is joined to the extruded tank section near the first tank end, and a second planar end cap is joined to the extruded tank section near the second tank end. Together, the extruded tank section and first and second end caps can at least partially define an internal tank volume. The first and second planar end caps are both arranged at non-perpendicular angles to the longitudinal direction.

Abstract: A heat exchange system and apparatus for a vehicle powertrain configured to exchange heat between a first fluid and a second fluid within a heat exchanger core formed by a plurality of stacked plates having separate channels for the first fluid and the second fluid. The heat exchanger system includes multiple heat exchangers, one of which is connected to a both the inlet and the outlet of a vehicle powertrain component, another of which is fluidly connected or at least partially disconnected from the vehicle component according to the mode of operation of the heat exchange system. The heat exchanger connected to the vehicle component includes a jumper tube to return the first fluid to the vehicle component through a core of the heat exchanger.

Abstract: A heating and cooling system includes a heat exchange section to transfer heat between refrigerant and air in both a heating mode and a cooling mode. The heat exchange section includes at least two refrigerant passes. Refrigerant is circuited through the refrigerant passes in the same direction in both the heating mode and the cooling mode, so that the overall flow orientation between the refrigerant passes and the air is a counter-flow orientation in both the heating mode and the cooling mode.

Abstract: A method of cooling an electronics cabinet includes inducing a flow of cooling air to enter into the electronics cabinet, passing the flow of cooling air over electronic modules arranged within the electronics cabinet to convectively transfer heat to the flow of cooling air from the electronic modules, and directing the flow of cooling air through a door heat exchanger at an end of the electronics cabinet to exhaust the flow of cooling air from the cabinet. A first coolant flow is directed through the door heat exchanger, and heat is transferred from the flow of cooling air to the first coolant flow as they pass through the door heat exchanger. A second coolant flow is circulated through a coolant loop that is arranged within the electronics cabinet, and passes though cold plates that are joined to at least some of the electronic modules to transfer heat from those modules to the second coolant flow.

Abstract: A battery cooling system includes several battery cooling plates connected to a coolant manifold and coolant chiller. The coolant chiller is configured to remove heat from a flow of coolant that circulates through the battery cooling system. The coolant manifold has a first and a second chamber that both extend in a longitudinal direction and that are spaced apart and separated by an air gap. The first chamber receives a flow of chilled coolant from the coolant chiller, and the second chamber delivers to the coolant chiller a flow of coolant to be chilled. Plastic connectors in one-to-one correspondence with the battery cooling plates are mounted to the coolant manifold to fluidly couple the first and second chambers of the coolant manifold to the battery cooling plates.