Abstract: A heat exchanger has at least one channel structure defining a fluid flow passage. Each channel structure includes first and second thermally conductive plates, with a fluid flow passage defined by a space between the inner surfaces of the first and second plates. At least one electrical heating element is provided outside the fluid flow passage and located adjacent to the outer surface of the first plate, such that heat from the heating element is transferred through the first plate to the fluid in the flow passage during use of the heat exchanger. In some embodiments, the first plate of the first channel structure is arranged opposite to the first plate of the second channel structure, with spacers received between the first and second channel structures. At least one of the spacers may have fluid transfer openings to provide flow communication between the first and second channel structures.

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 assembly includes a cooling plate with at least one outer heat transfer surface adapted for thermal contact with one or more heat-generating substrates. A fluid flow path extends from an inlet port to an outlet port, with a plurality of cooling zones spaced apart along the fluid flow path, each cooling zone including a heat transfer element such as a corrugated fin sheet in contact with the inner surface of the first plate wall. Manifold spaces are defined proximate to the inlet and outlet ports, and between adjacent cooling zones. One or more bypass flow passages are provided between upstream and downstream ends of at least one cooling zone, to divert a portion of the heat transfer fluid from flowing through the cooling zone. The volume of fluid flow bypassing one or more cooling zones is calibrated to improve temperature uniformity of the heat-generating substrates.

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. 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 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 for thermal management of battery units made-up of a plurality of battery cells or battery cell containers housing one or more battery cells. 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. In some embodiments the heat exchanger has two pairs of inlet and outlet manifolds, 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 two-pass heat exchanger with calibrated bypass is disclosed for cooling heat-generating substrates and/or for heating a heat transfer fluid. The heat exchanger has first and second outer plate walls and an intermediate plate wall located between and spaced from the outer plate walls in the thickness dimension of the heat exchanger, and with inlet and outlet ports at the same end. An input flow passage is defined between the first outer plate wall and the intermediate plate wall, and a return flow passage is defined between the second outer plate wall and the intermediate plate wall. The first and second fluid flow passages are in a U-flow, stacked arrangement. At least one bypass opening extends through the intermediate plate wall between the input and return flow passages, and configured to permit a portion of the heat transfer fluid to bypass portions of the input and return flow passages.

Abstract: An aluminum heat exchanger includes first and second plates with inner and outer surfaces, which are joined by brazing and define at least one fluid flow passage. The first and second plates each comprise a core layer of aluminum or an aluminum alloy having a melting temperature greater than an aluminum brazing temperature. The first plate also includes a first outer clad layer defining the outer surface of the first plate. The first outer clad layer is solderable to a metal layer of an object to be cooled and includes nickel or copper. A second outer clad layer is located between the first outer clad layer and the core layer and is roll bonded to at least the second outer clad layer. A manufacturing method includes brazing first and second plates, where the layers of the first plate are roll bonded and the first plate is optionally formed before brazing.

Abstract: Methods and system are provided for a heat exchanger. In one example, a system, comprises a mobile electronic device comprising a front cover and a rear cover, a heat exchanger arranged between the front cover and the rear cover, the heat exchanger comprising a fluid chamber arranged between an inner surface of a first plate and an inner surface of a second plate, and a wick material arranged within the fluid chamber, the wick material comprising a sintered material configured to allow a plurality of fluid passages to extend therethrough.

Abstract: A heat exchanger assembly includes a cooling plate with at least one outer heat transfer surface adapted for thermal contact with one or more heat-generating substrates. A fluid flow path extends from an inlet port to an outlet port, with a plurality of cooling zones spaced apart along the fluid flow path, each cooling zone including a heat transfer element such as a corrugated fin sheet in contact with the inner surface of the first plate wall. Manifold spaces are defined proximate to the inlet and outlet ports, and between adjacent cooling zones. One or more bypass flow passages are provided between upstream and downstream ends of at least one cooling zone, to divert a portion of the heat transfer fluid from flowing through the cooling zone. The volume of fluid flow bypassing one or more cooling zones is calibrated to improve temperature uniformity of the heat-generating substrates.

Abstract: An electronic device includes a heat-generating electronic component, a heat spreader and a heat sink. The heat spreader has an area at least about 4 times greater than the heat-generating component. A first surface of the heat spreader is in thermal contact with the first surface of the heat-generating component along a first, non-dielectric interface. The heat sink has greater mass than the heat spreader and comprises one or more layers of thermally conductive material. A first surface of the heat sink is in thermal contact with the second surface of the heat spreader along a second interface having greater area than the first interface. Dielectric thermal interface material is provided at the second interface in direct contact with the heat spreader and the heat sink, such that the second interface is dielectric.

Abstract: An LED device includes a multi-sided heat spreader element with a longitudinal multi-sided wall at least partly enclosing an internal space, with a plurality of LEDs mounted to the outer surface the heat spreader element, and a flow space for a cooling medium in the internal space. The tubular heat spreader element has at least one layer of a thermally conductive metal which is bendable from a flat shape to the multi-sided shape. The multi-sided shape may be tubular with a smoothly curved or multi-faceted polygonal wall. The wall of the LED device may incorporate two-phase cooling elements such as vapor chambers to maintain the LEDs at a constant temperature, and may include a temperature-controlled fan unit to control the LED temperature, and also control the wavelength and frequency of light emitted by the LEDs. A method for manufacturing the LED device is also disclosed.

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 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.

Abstract: A heat exchanger for cooling a heat-generating component includes first and second plates, each having a core layer of a first metal and an inner clad layer of a lower melting second metal, which is inert to the working fluid contained in a fluid chamber of the heat exchanger. The outer peripheral sealing surfaces of the first and second plates are joined by welding, wherein the weld joint is fluidly isolated from the fluid chamber by a layer of the second metal in an area adjacent to the weld joint. In some embodiments, the heat exchanger includes liquid flow passages and primary and secondary gas flow passages, each secondary passage providing communication between primary gas flow passages. The gas and liquid flow passages may be defined by a wick material having hydrophilic areas and non-wicking areas of reduced thickness. A method of manufacturing is also disclosed.

Abstract: An integrated gas management device (GMD) for a fuel cell has a gas-to-gas humidifier for transferring water from a second gas to a first gas; and a heat exchanger attached to a first end of the humidifier core for cooling the first gas. The GMD may optionally have a thermal isolation plate between the heat exchanger and the first end of the humidifier core. The GMD further has a bypass line to allow the first gas to bypass the humidifier. The first gas may be cathode charge air and the second gas may be cathode exhaust.

Abstract: A heat exchanger for use with at least two battery modules, each of the battery modules comprising at least one battery cell housed within a rigid container, the heat exchanger defining an internal fluid passage for a heat exchanger fluid and having at least one compliant region that is configured to be compressed to facilitate thermal contact between the heat exchanger and the two battery modules.

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 fluid channel formed with generally triangular-shaped performance enhancement features is disclosed. The fluid channels may be incorporated into heat exchanger or humidifier devices, the performance enhancement features generally having heat transfer and/or mass transfer performance enhancement applications. The heat transfer or mass transfer enhancement features are formed along the inner surfaces of the fluid flow passages of either the heat exchanger or humidifier plates and generally have sharp leading edges that create vortices in the fluid flowing through the passages. The heat or mass transfer enhancements protrude out of the inner surface of the fluid flow passages while leaving the outer surface of the fluid channel free of perforations. Alternatively, heat or mass transfer enhancements may be formed on separate inserts that are affixed to the inner surface of the fluid flow passages.

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 plate and frame style heat exchanger is disclosed herein the heat exchanger is formed by a plurality of heat exchange plates and frame members that are alternatingly stacked together to form fluid channel members. The frame members are formed by lengths of material that are formed or bent into the desired configuration for providing a first fluid tight seal around the periphery of the plates and a second fluid tight seal around respective fluid openings formed in the heat exchanger plates in order to achieve the desired flow configuration through the heat exchanger. In some embodiments the frame members are made up of two mating frame portions that join together in a self-aligning and self-fixturing relationship to facilitate assembly.