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 exchanger such as a cold plate or ICE plate has an integrated electric heating element provided on an external heater support surface of the heat exchanger. The external heater support surface is directly opposite to an internal surface of the heat exchanger which at least partly defines one or both of the inlet manifold and the outlet manifold. A thermal management system for a vehicle having a plurality of rechargeable battery units includes a circulation loop for circulating a first volume of the heat transfer fluid, and a plurality of battery heat exchangers, including a first heat exchanger with an integrated electric heating element. A sub-loop of the circulation loop includes the internal fluid flow passage of the first heat exchanger, and is adapted for a second, smaller volume of the heat transfer fluid.

Abstract: A heat exchanger such as a cold plate or ICE plate has an integrated electric heating element provided on an external heater support surface of the heat exchanger. The external heater support surface is directly opposite to an internal surface of the heat exchanger which at least partly defines one or both of the inlet manifold and the outlet manifold. A thermal management system for a vehicle having a plurality of rechargeable battery units includes a circulation loop for circulating a first volume of the heat transfer fluid, and a plurality of battery heat exchangers, including a first heat exchanger with an integrated electric heating element. A sub-loop of the circulation loop includes the internal fluid flow passage of the first heat exchanger, and is adapted for a second, smaller volume of the heat transfer fluid.

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 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 exchanger such as a cold plate or ICE plate has an integrated electric heating element provided on an external heater support surface of the heat exchanger. The external heater support surface is directly opposite to an internal surface of the heat exchanger which at least partly defines one or both of the inlet manifold and the outlet manifold. A thermal management system for a vehicle having a plurality of rechargeable battery units includes a circulation loop for circulating a first volume of the heat transfer fluid, and a plurality of battery heat exchangers, including a first heat exchanger with an integrated electric heating element. A sub-loop of the circulation loop includes the internal fluid flow passage of the first heat exchanger, and is adapted for a second, smaller volume of the heat transfer fluid.

Abstract: A heat exchanger is comprised of two heat exchanger sections, at least one of which is provided with a floating header to accommodate differential thermal expansion. The two heat exchanger sections are enclosed by an inner shell wall, and an external connecting passage is provided outside the inner shell wall, through which one of the fluids flows between the two heat exchanger sections. The external connecting passage is enclosed by an outer shell. The inner wall is provided with openings which communicate with the external connecting passage. The openings may be in the form of a substantially continuous gap or discrete openings. Specific examples of heat exchangers with this construction include a steam generator, a steam generator and combined catalytic converter, and a water gas shift reactor.

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 recovery device such as an EGHR device includes a bypass valve, a gas/liquid heat exchanger and a flow duct. The flow duct has an open top and an open bottom. A top surface of the duct seals to a surface surrounding an opening of a gas flow conduit, such as an exhaust pipe. A duct wall extends from the top surface to the bottom surface, to which the heat exchanger is secured. The flow duct provides a passage through gas flows between the gas flow conduit and the heat exchanger. The bypass valve is mounted in the flow duct and is movable between a bypass position and a heat exchange position. The bypass valve may be mounted adjacent to the top or bottom of the duct, and may be a butterfly-type valve, a one-sided flap valve, or a pair of one-sided flap valves.

Abstract: A heat exchanger is comprised of two heat exchanger sections, at least one of which is provided with a floating header to accommodate differential thermal expansion. The two heat exchanger sections are enclosed by an inner shell wall, and an external connecting passage is provided outside the inner shell wall, through which one of the fluids flows between the two heat exchanger sections. The external connecting passage is enclosed by an outer shell. The inner wall is provided with openings which communicate with the external connecting passage. The openings may be in the form of a substantially continuous gap or discrete openings. Specific examples of heat exchangers with this construction include a steam generator, a steam generator and combined catalytic converter, and a water gas shift reactor.

Abstract: A heat exchanger is comprised of two heat exchanger sections, at least one of which is provided with a floating header to accommodate differential thermal expansion. The two heat exchanger sections are enclosed by an inner shell wall, and an external connecting passage is provided outside the inner shell wall, through which one of the fluids flows between the two heat exchanger sections. The external connecting passage is enclosed by an outer shell. The inner wall is provided with openings which communicate with the external connecting passage. The openings may be in the form of a substantially continuous gap or discrete openings. Specific examples of heat exchangers with this construction include a steam generator, a steam generator and combined catalytic converter, and a water gas shift reactor.

Abstract: A co-axial gas-liquid heat exchanger such as a charge air cooler comprises at least three concentric tubes forming at least two annular flow passageways. One end of the inner tube is rigidly attached to the middle tube by a thermal expansion connector including an inner connecting portion secured to the first end of the inner tube, an outer connecting portion secured to an inner surface of the middle tube; and one or more webs connecting the inner connecting portion to the outer connecting portion. The webs extend across the annular gas flow passageway but permit the hot gas to flow therethrough. The other end of the inner tube is free to expand in the longitudinal direction, relative to the middle and outer tubes. In some embodiments, the inner connecting portion forms part of a central plug portion which blocks an end of the inner tube.

Abstract: A heat recovery device comprises a gas flow conduit, a gas/liquid heat exchanger and a gas diverter valve provided in the gas flow conduit, the valve being movable between a bypass position and a heat exchange position. The gas flow conduit includes a divergent branch point at which it is divided into a bypass branch conduit and a heat exchange branch conduit. The bypass branch conduit bypasses the heat exchanger, and the heat exchange branch conduit includes an upstream conduit portion and a downstream conduit portion. The gas flow direction from the upstream conduit portion into the gas inlet opening of the heat exchanger diverges in a direction away from the overall gas flow direction, permitting the heat exchanger to be spaced away from the exhaust gas conduit.

Abstract: A heat recovery device such as an EGHR device includes a bypass valve, a gas/liquid heat exchanger and a flow duct. The flow duct has an open top and an open bottom. A top surface of the duct seals to a surface surrounding an opening of a gas flow conduit, such as an exhaust pipe. A duct wall extends from the top surface to the bottom surface, to which the heat exchanger is secured. The flow duct provides a passage through gas flows between the gas flow conduit and the heat exchanger. The bypass valve is mounted in the flow duct and is movable between a bypass position and a heat exchange position. The bypass valve may be mounted adjacent to the top or bottom of the duct, and may be a butterfly-type valve, a one-sided flap valve, or a pair of one-sided flap valves.

Abstract: A heat exchanger is comprised of two heat exchanger sections, at least one of which is provided with a floating header to accommodate differential thermal expansion. The two heat exchanger sections are enclosed by an inner shell wall, and an external connecting passage is provided outside the inner shell wall, through which one of the fluids flows between the two heat exchanger sections. The external connecting passage is enclosed by an outer shell. The inner wall is provided with openings which communicate with the external connecting passage. The openings may be in the form of a substantially continuous gap or discrete openings. Specific examples of heat exchangers with this construction include a steam generator, a steam generator and combined catalytic converter, and a water gas shift reactor.

Abstract: A co-axial gas-liquid heat exchanger such as a charge air cooler comprises at least three concentric tubes forming at least two annular flow passageways. One end of the inner tube is rigidly attached to the middle tube by a thermal expansion connector including an inner connecting portion secured to the first end of the inner tube, an outer connecting portion secured to an inner surface of the middle tube; and one or more webs connecting the inner connecting portion to the outer connecting portion. The webs extend across the annular gas flow passageway but permit the hot gas to flow therethrough. The other end of the inner tube is free to expand in the longitudinal direction, relative to the middle and outer tubes. In some embodiments, the inner connecting portion forms part of a central plug portion which blocks an end of the inner tube.

Abstract: A bypass valve for a heat exchanger including a plurality of parallel tubular members comprises a housing having a hollow plug portion adjacent to an actuator portion. The actuator comprises a reciprocating plunger extending into the plug portion and a solenoid having a central actuator shaft attached to the plunger, wherein the actuator shaft extends upon energization of the solenoid so that the plunger prevents bypass flow through the valve. The valve also comprises a temperature sensor for sensing a temperature of the fluid flowing through the heat exchanger, the temperature sensor being electrically coupled to the solenoid through one or more conductors, wherein the temperature sensor is located at the first end of the actuator shaft and the conductors extend through the hollow interior of the actuator shaft to the second end thereof.

Abstract: A heat exchanger includes: a bypass valve; a stack of standard tubes; and, in the stack, a pair of stacked-together adapter tubes. Each standard tube end has spaced-apart walls including openings. Each adapter tube end has: a wall including an opening; and a passage. At one end of the pair, the passages communicate with one another and the openings communicate with the openings in adjacent standard tubes; at the other end, the openings communicate with the openings in adjacent standard tubes. The valve includes a plug with opposed plug walls, one plug wall having one of an inlet and outlet, the plug being disposed with its walls between and at said other end of the pair and with the inlet and outlet communicating with the passages. An actuator is adjacent to the plug and has a reciprocating plunger for selectively blocking at least said one of the inlet and outlet.

Abstract: A bypass valve for a heat exchanger including a plurality of parallel tubular members comprises a housing having a hollow plug portion adjacent to an actuator portion. The actuator comprises a reciprocating plunger extending into the plug portion and a solenoid having a central actuator shaft attached to the plunger, wherein the actuator shaft extends upon energization of the solenoid so that the plunger prevents bypass flow through the valve. The valve also comprises a temperature sensor for sensing a temperature of the fluid flowing through the heat exchanger, the temperature sensor being electrically coupled to the solenoid through one or more conductors, wherein the temperature sensor is located at the first end of the actuator shaft and the conductors extend through the hollow interior of the actuator shaft to the second end thereof.

Abstract: A bypass valve for a heat exchanger including a plurality of parallel tubular members comprises a housing having a hollow plug portion adjacent to an actuator portion. The actuator comprises a reciprocating plunger extending into the plug portion and a solenoid having a central actuator shaft attached to the plunger, wherein the actuator shaft extends upon energization of the solenoid so that the plunger prevents bypass flow through the valve. The valve also comprises a temperature sensor for sensing a temperature of the fluid flowing through the heat exchanger, the temperature sensor being electrically coupled to the solenoid through one or more conductors, wherein the temperature sensor is located at the first end of the actuator shaft and the conductors extend through the hollow interior of the actuator shaft to the second end thereof.