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: Methods and systems are provided for heat exchangers including a first outer plate, a second outer plate, and an intermediate plate. The intermediate plate is positioned between the outer plates. Fluid flow passages are formed between the intermediate plate and each of the outer plates.

Abstract: A heat exchanger has a fluid flow passage having an inlet and an outlet, and with a first plate and a second plate in opposed facing relation to one another. The fluid flow passage is defined by a space between the inner surfaces of the first and second plates. An electrical heating element is outside the fluid flow passage and adjacent to the outer surface of the first plate, such that heat produced by the electrical heating element is transferred through the first plate to the fluid in the fluid flow passage during use of the heat exchanger. In an embodiment, the first plate has an opening to receive a heater plate component including a first plate portion having an inner surface bonded to a turbulence-enhancing insert and an outer surface bonded to the electrical heating element.

Abstract: A heat transfer surface for use in conjunction with a heat exchanger is disclosed. The heat transfer surface a corrugated member where rows of corrugations that are offset relative to each other forming at least an alternating series of first and second rows or first, second and third rows. In some embodiments the heat transfer surface includes a heat transfer enhancement feature disposed within individual corrugations of the corrugated member to provide a more turbulent or tortuous fluid flow path through the heat transfer surface. In some example embodiments the heat transfer enhancement feature is a ridge disposed in the planar portions of at least some of the rows of corrugations. In other example embodiments the planar fin portions are porous fin surfaces. In other embodiments, the corrugated member cooperates with heat transfer enhancement features in the form of triangular protuberances disposed on their inner surfaces of spaced apart plates.

Abstract: A gas-liquid heat exchanger such as a charge air cooler has a core comprising a stack of flat tubes defining liquid coolant flow passages, and a plurality of open-ended gas flow passages between the flat tubes. An endmost gas flow passage is defined between an end plate of the core and an adjacent flat tube, such that the endmost gas flow passage is in contact with only said adjacent one of said flat tubes. A blocking element extends along either the front face or the rear face of the core and at least partly blocking the endmost gas flow passage. Each flat tube may comprise a pair of core plates, at least one including a flap projecting into a gas flow passage and covering a gas bypass channel between the edge of the turbulence-enhancing insert and the sides of a coolant manifold.

Abstract: A heat exchanger plate having a planar plate having an inlet and outlet proximate to a first edge of the heat exchanger plate. The planar plate having a plurality of ribs and a plurality of channels, with the plurality of channels being in a plane different from the planar plate. The plurality of channels being in fluid communication from the inlet to the outlet permitting fluid flow from the inlet to the outlet. A protrusion coupled to the planar plate proximate to the first edge of the heat exchanger plate and laterally extending from an axis, with the heat exchanger plate being susceptible to bending about the axis.

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: Methods and systems are provided for a heat exchanger. In one example, the heat exchanger may dissipate energy generated by a battery module and may include a first plate and a second plate arranged in opposed facing relation to one another. A plurality of flow passages may be formed between the first and second plates, the plurality of flow passages including at least one multipass fluid flow passage with at least three longitudinally-extending legs.

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 counterflow heat exchanger for battery thermal management has a base plate, a cover plate and manifold cover. The base plate includes alternating first and second longitudinal fluid flow passages. The cover plate is sealed to the base plate to enclose the first and second fluid flow passages, and includes a first fluid opening and a plurality of second fluid openings arranged at spaced apart intervals across a width of the cover plate. The manifold cover includes an embossment surrounded by a peripheral flange which is sealed to the cover plate and surrounds at least the plurality of second fluid openings. The interior of the embossment defines a manifold chamber in flow communication with the second fluid openings in the cover plate. The top of the manifold cover has at least a second fluid opening in flow communication with the plurality of second fluid openings through the manifold chamber.

Abstract: A heat exchanger for thermal management of battery units made-up of a plurality of battery cells or containers housing one or more battery cells is disclosed. The heat exchanger has a main body portion formed by a pair of outer plates and an intermediate plate defining a primary heat transfer surface on either side of the heat exchanger for contacting a corresponding surface of at least one of the battery cells or containers. The intermediate plate together with the outer plates forming a plurality of alternating first and second fluid flow passages the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages. The first and second fluid flow passages are formed on opposite sides of the intermediate plate and are fluidly interconnected at corresponding ends creating a counter-flow arrangement through the main body portion of the heat exchanger.

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 plate having a planar plate having an inlet and outlet proximate to a first edge of the heat exchanger plate. The planar plate having a plurality of ribs and a plurality of channels, with the plurality of channels being in a plane different from the planar plate. The plurality of channels being in fluid communication from the inlet to the outlet permitting fluid flow from the inlet to the outlet. A protrusion coupled to the planar plate proximate to the first edge of the heat exchanger plate and laterally extending from an axis, with the heat exchanger plate being susceptible to bending about the axis.

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 for thermal management of battery units made-up of plurality of battery cells or battery cell containers housing one or more battery cells 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 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 having an integrated support structure particularly suited for thermal management of heat generating components such as battery thermal management applications or thermal management of other electronic components is disclosed. The heat exchanger includes a top plate and a base tray defining a plurality of fluid channels that extend between an inlet manifold area and an outlet manifold area. The top plate has a first side defining a primary heat transfer area and a second side for effecting a sealing relationship between the top plate and the base tray. In some instances, the top plate includes a thermally conductive material while the base tray includes a non-thermally conductive material. In some instances the base tray cooperates with a cover portion to define an enclosure for housing the heat generating components.

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.