Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels define a first flow path, and each of the second fluid channels define a second flow path. A portion of the first flow paths overlap, and are oriented opposite to, a portion of the second flow paths. Another portion of the first flow paths overlap, and are oriented transverse to, another portion of the second flow paths.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels are fluidly coupled to two manifolds, and each of the second fluid channels are fluidly coupled to two more manifolds. One of the manifolds has a reduced interior volume to control and normalize fluid flow through the heat exchanger.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels are fluidly coupled to an inlet manifold and an outlet manifold. At least one of the manifolds is provided with surface features that improve heat exchange within the manifold. The surface features may be, for example, projections such as fins that increase surface area contact between the fluid in the manifold and the interior wall of the manifold.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body defining a first fluid inlet port, a first fluid outlet port, a second fluid inlet port, and a second fluid outlet port, wherein each of these fluid ports are integrally formed with the main body. A plurality of plates are stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body and are in fluid communication with the first fluid inlet port. Second fluid channels are defined by gaps in the material of the main body and are in fluid communication with the second fluid inlet port. The first fluid channels and the second fluid channels are interposed between the plates in alternating fashion along the stacked arrangement.

Abstract: A stiffener for a heat exchanger includes a top plate and at least two legs extending from opposing sides of the top plate. Each of the at least two legs includes a bent portion, an angled portion, and a straight portion. The bent portion attaches the leg to the top plate. The angled portion increases a width of the stiffener from a width of the top plate. The straight portion extends perpendicular to a plane of the top plate.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels are fluidly coupled to an inlet manifold and an outlet manifold. A jumper pipe is fluidly coupled to and between an inlet port and the inlet manifold. In an embodiment, the jumper pipe is curved at one end thereof to intersect the inlet manifold at a generally perpendicular angle.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels define a first flow path, and each of the second fluid channels define a second flow path. A portion of the first flow paths overlap, and are oriented opposite to, a portion of the second flow paths. Another portion of the first flow paths overlap, and are oriented transverse to, another portion of the second flow paths.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels are fluidly coupled to an inlet manifold and an outlet manifold. At least one of the manifolds is provided with surface features that improve heat exchange within the manifold. The surface features may be, for example, projections such as fins that increase surface area contact between the fluid in the manifold and the interior wall of the manifold.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body defining a first fluid inlet port, a first fluid outlet port, a second fluid inlet port, and a second fluid outlet port, wherein each of these fluid ports are integrally formed with the main body. A plurality of plates are stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body and are in fluid communication with the first fluid inlet port. Second fluid channels are defined by gaps in the material of the main body and are in fluid communication with the second fluid inlet port. The first fluid channels and the second fluid channels are interposed between the plates in alternating fashion along the stacked arrangement.

Abstract: A heat exchanger is provided with a unitary, single-piece structure that can be formed via 3D printing, for example. The heat exchanger includes a main body a plurality of plates stacked and integrally formed with the body. First fluid channels are defined by gaps in the material of the main body, and second fluid channels are defined by gaps in the material of the main body and are stacked with the first fluid channels in alternating fashion, separated by the plates. Each of the first fluid channels are fluidly coupled to two manifolds, and each of the second fluid channels are fluidly coupled to two more manifolds. One of the manifolds has a reduced interior volume to control and normalize fluid flow through the heat exchanger.

Abstract: A wax motor thermostat for an engine cooling system. The thermostat includes a cylinder having at least a first wax portion and a second wax portion each configured to expand at different temperatures. A piston is movable in response to expansion of the first and second wax portions to move the wax motor thermostat from a closed position to a fully open position or a partially open position between the closed and fully open positions to allow coolant to flow through the wax motor thermostat.

Abstract: A stiffener for a heat exchanger includes a top plate and at least two legs extending from opposing sides of the top plate. Each of the at least two legs includes a bent portion, an angled portion, and a straight portion. The bent portion attaches the leg to the top plate. The angled portion increases a width of the stiffener from a width of the top plate. The straight portion extends perpendicular to a plane of the top plate.

Abstract: A wax motor thermostat for an engine cooling system. The thermostat includes a cylinder having at least a first wax portion and a second wax portion each configured to expand at different temperatures. A piston is movable in response to expansion of the first and second wax portions to move the wax motor thermostat from a closed position to a fully open position or a partially open position between the closed and fully open positions to allow coolant to flow through the wax motor thermostat.

Abstract: A heat exchanger includes a core including a plurality of tubes and a plurality of air passages, an air inlet portion in fluid communication with the air passages, and an air outlet portion in fluid communication with the air passages. The tubes and the air passages are alternately arranged to be parallel with each other. The core extends along a core plane defined by the tubes and the air passages. The core is disposed such that the core plane is parallel to a vehicle horizontal plane. Outside air flows through the air passages in a first direction. Thermal medium flows through the tubes in a second direction opposite to the first direction. The air inlet portion is open at a front side of the vehicle or a lateral side of the vehicle. The air outlet portion is open at the front side of the vehicle or the lateral side of the vehicle.