Abstract: A heat exchanger having a conical-shaped core is disclosed. A first set of flow passages is formed between mating conical-shaped core plates, the mating plates forming plate pairs that are spaced apart from each other forming a second set of flow passages therebetween. A pair of oppositely disposed fluid openings are provided for inletting/discharging a fluid to/from the heat exchanger in a co-axial manner, the fluid openings being interconnected by a pair of fluid manifolds formed in the outer perimeter of the core, the second set of flow passages and a fluid manifold formed centrally through the heat exchanger. A second set of inlet/outlet manifolds formed within the perimeter of the core are interconnected by the first set of flow passages. Flow through the first set flow passages is peripheral around the perimeter of the conically-shaped core plates while flow through the second set of flow passages is along the angle defined by the conical-shaped 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 manifold structure for re-directing a fluid stream between first and second ends of a manifold cavity for delivering or discharging a fluid to or from a corresponding fluid transmitting device, such as a heat exchanger is disclosed. In particular, a a flow box enclosing a fluid transmitting device is disclosed wherein an incoming or outgoing fluid is re-directed between first and second directions when being delivered to or discharged from the enclosed fluid transmitting device In one embodiment, the manifold structure includes a first curved surface having a concave curvature for redirecting a fluid stream from a first direction to a second direction. In another embodiment, the manifold structure includes a second curved surface having a convex curvature that is disposed in facing, spaced-apart relationship to the first curved surface, the first and second curved surfaces together inducing swirling movement into the incoming or outgoing fluid stream.

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 counterflow heat exchanger for battery thermal management has a base plate, 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 comprises 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 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.

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 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 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 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 battery cell heat exchanger formed by a pair of mating plates that together form an internal tubular flow passage. The tubular flow passage is generally in the form of a serpentine flow passage extending between an inlet end and an outlet end and having generally parallel flow passage portions interconnected by generally U-shaped flow passage portions. The flow passage provides a graded heat transfer surface within each generally parallel flow passage portion and/or a variable channel width associated with each flow passage portion to provide improved temperature uniformity across the surface of the heat exchanger. The graded heat transfer surface may be in the form of progressively increasing the surface area associated with the individual flow passage portions with heat transfer enhancement features or surfaces arranged within the flow passage portions. The channel width and/or height may also be varied so as to progressively decrease for each flow passage portion.

Abstract: A heat exchanger comprises: (a) at least one plate pair comprising a first plate and a second plate and having a first end and a second end; (b) a fluid flow passage for flow of a first fluid defined between the first plate and the second plate of each of said plate pairs; (c) an inlet opening and an outlet opening provided in each of said plate pairs, wherein the fluid flow passage extends between the inlet opening and the outlet opening, and wherein the inlet opening and the outlet opening in each said plate pair are proximate to the first end; (d) an elongate flow barrier separating the fluid flow passage of each said plate pair into an inlet portion in which the inlet is located, and an outlet portion in which the outlet is located, wherein the flow barrier extends from the first end to a terminal end proximate to the second end of the plate pair, and wherein the flow barrier includes a gap through which fluid flow communication is provided between the inlet portion and the outlet portion of the fluid f

Abstract: A manifold structure for re-directing a fluid stream between first and second ends of a manifold cavity for delivering or discharging a fluid to or from a corresponding fluid transmitting device, such as a heat exchanger is disclosed. In particular, a manifold structure formed within a flow box enclosing a fluid transmitting device is disclosed wherein the manifold structure re-directs an incoming or outgoing fluid to or from the fluid transmitting device, such as a heat exchanger, housed within the flow box. In one embodiment, the manifold structure comprises a first curved surface having a concave curvature for redirecting a fluid stream from a first direction to a second direction or vice versa. In another embodiment, the manifold structure further comprises a second curved surface having a convex curvature in facing, spaced-apart relationship to the first curved surface, the corresponding first and second curved surfaces inducing swirling movement into the fluid stream.

Abstract: A heat exchanger having a conical-shaped core is disclosed. A first set of flow passages is formed between mating conical-shaped core plates, the mating plates forming plate pairs that are spaced apart from each other forming a second set of flow passages therebetween. A pair of oppositely disposed fluid openings are provided for inletting/discharging a fluid to/from the heat exchanger in a co-axial manner, the fluid openings being interconnected by a pair of fluid manifolds formed in the outer perimeter of the core, the second set of flow passages and a fluid manifold formed centrally through the heat exchanger. A second set of inlet/outlet manifolds formed within the perimeter of the core are interconnected by the first set of flow passages. Flow through the first set flow passages is peripheral around the perimeter of the conically-shaped core plates while flow through the second set of flow passages is along the angle defined by the conical-shaped plates.