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.

Abstract: A liquid cooler having a heat exchanger core located within a housing, the heat exchanger core secured to the housing by fastening points on the housing. The heat exchanger core having a stack of plate pairs or tubes, and the core also having ribs arranged in between the plate pairs or tubes. A cover plate with apertures is arranged on the heat exchanger core. The heat exchanger core is located within an insertion opening of the housing. An adapter rests on the cover plate in a sealing manner. The adapter includes at least one of an inlet port and an outlet port. The adapter is fastened to the housing at the fastening points, and provides a fluid connection to the apertures and the tubes or plate pairs.

Abstract: A heat exchanger assembly, in particular an exhaust gas cooler, having a gas inlet pipe attached to an inlet diffuser to improve flow distribution of the gas in a case with a heat exchanger core within. The gas inlet pipe configured to disrupt the momentum of flow of the gas due to at least one bend upstream of the inlet diffuser. The gas inlet pipe including at least two intermediate bends which define multiple section of the gas inlet pipe, at least two of the sections redirecting flow of the gas before an outlet of the gas inlet pipe to more evenly distribute the gas at the outlet of the gas inlet pipe upstream of the inlet diffuser.

Abstract: A cooling module is coupled to an engine system and a Rankine cycle waste heat recovery system. The cooling module includes a heat exchanger for cooling a fluid of the engine system and a condenser for cooling a working fluid of the Rankine cycle waste heat recovery system, both of which extend in a width direction of the cooling module and are porous to a flow of cooling air in a depth direction of the cooling module. The condenser includes a first tubular header that extends in a height direction of the cooling module. A working fluid transfer tube fluidly couples the first tubular header to the Rankine waste heat recovery cycle system. The working fluid transfer tube has a first portion extending in the depth direction and a second portion extending in the height direction, the second portion being adjacent to the first tubular header in the width direction.

Abstract: A heat exchanger that includes first and second headers, a first flow conduit fluidly connecting the first and second headers to allow for a flow of a first fluid through the heat exchanger, the first flow conduit being bounded by a first generally planar wall section extending between the first and second headers, a second flow conduit to allow for a flow of the second fluid through the heat exchanger, the second flow conduit being bounded by a second generally planar wall section spaced apart from the first generally planar wall section to define a gap therebetween, and a thermally conductive structure arranged within the gap and joined to the first and second generally planar wall sections to transfer heat therebetween. The thermally conductive structure is isolated from the first fluid by the first generally planar wall section and from the second fluid by the second generally planar wall section.

Abstract: A heat exchanger is constructed from a plurality of plate pairs stacked to form air flow passages between adjacent ones of the plurality of plate pairs and cooling fluid flow paths within each of the plurality of plate pairs. The cooling fluid flow paths have a first portion along one longitudinal edge of each plate pair, a second portion along an opposing longitudinal edge each plate pair, a third portion extending through the heat exchange section between the first and second portions, and a fourth portion extending between the first and second portions along one lateral edge of each plate pair and bypassing the third portion. Flow barriers are arranged within each plate pair to at least partially define the third and fourth portions.

Abstract: A power generation system having a combustion engine with a Rankine bottoming cycle, the system including a first flow path for a process fluid and a second flow path for a working fluid, and a heat exchanger arranged along both the first and the second flow paths to transfer waste heat from the process fluid to the working fluid. The heat exchanger includes a first flow conduit being bounded by a first wall section and configured to convey the process fluid, a second flow conduit to convey the working fluid, the second flow conduit being bounded by a second wall section spaced apart from the first wall section to define a gap therebetween, and a thermally conductive structure arranged within the gap and joined to the first and second wall sections to transfer heat therebetween, the gap being fluidly isolated from both the process fluid and the working fluid.

Abstract: A thermal management unit for a vehicle powertrain includes an integrated oil heater, a control valve, and a pressure relief valve. A remote oil cooler is connected to fluid ports of the thermal management unit. Transmission oil is received into the thermal management unit and is directed to one or both of the transmission oil heater and the transmission oil cooler. A portion of the flow of oil can be internally bypassed through the pressure relief valve to maintain the pressure of the oil below a threshold. The flow of oil is directed through the control valve after having been heated and/or cooled, and the proportions of oil being directed through the oil heater and the oil cooler are determined by the temperature of the oil in the control valve.

Abstract: A heat exchanger for cooling a flow of compressed air using a liquid coolant includes a stack of coolant flow plates extending in a stacking direction. An enclosure surrounds the stack of coolant flow plates to at least partially define the flow path for the compressed air, and includes a first wall generally arranged in a plane parallel to the stacking direction, a second wall joined to the first wall and generally arranged in a second plane perpendicular to the stacking direction, a coolant port provided on an external surface of the first wall, an aperture provided on an internal surface of the second walls, and a coolant flow path extending through the interior of both the first wall and the second wall between the coolant port and the aperture.

Abstract: A heat exchanger includes a heat exchanger core having two core sections, each core section having coolant flow passages. A mounting bracket is arranged between the core sections, being joined to each core section. A housing for the heat exchanger core includes multiple housing sections joined together to define an air flow path. The mounting bracket is secured between the multiple housing sections.

Abstract: An engine system with exhaust gas recirculation includes a combustion engine, a flow mixer, and a turbocharger. An exhaust flow path and a charge air flow path each extend to an inlet of the flow mixer, and a mixed gas flow path extends between the outlet of the flow mixer and an intake manifold of the engine. A charge air heat exchanger is arranged along the charge air flow path to cool the charge air, and a mixed gas heat exchanger is arranged along the mixed gas flow path to cool mixed charge air and recirculated exhaust gas. The exhaust gas recirculation flow path does not extend through any heat exchangers.

Abstract: A heat exchanger includes first and second sets of parallel arranged tubes. The first set of tubes extends along a first arcuate path, the second set of tubes extends along a second arcuate path, and each one of the second set of tubes is aligned in a common plane with a corresponding one of the first set of tubes. Corrugated fin segments are arranged in spaces between adjacent tubes, and crests and troughs of the corrugated fin segments are joined to broad and flat faces of the tubes. In making the heat exchanger, the material of the corrugated fin segment is intermittently slit to define breaking points prior to arranging the corrugated fin segment between the tubes.