Abstract: Systems and methods for disrupting a flow of refrigerant within a heat exchanger assembly. One embodiment provides a method that includes receiving, with a controller, a first signal from a first sensor, the first signal indicative of a pressure of the refrigerant flowing through the heat exchanger. The method includes setting, with the controller, an operating frequency of a valve based on the first signal. The operating frequency includes a rate at which the valve actuates between a first valve position that sets a first refrigerant flow rate through the heat exchanger and a second valve position that sets a second refrigerant flow rate through the heat exchanger. The method includes controlling, with the controller, operation of a solenoid to actuate the valve at the operating frequency.

Abstract: Systems and methods for disrupting a flow of refrigerant within a heat exchanger assembly. One embodiment provides a method that includes receiving, with a controller, a first signal from a first sensor, the first signal indicative of a pressure of the refrigerant flowing through the heat exchanger. The method includes setting, with the controller, an operating frequency of a valve based on the first signal. The operating frequency includes a rate at which the valve actuates between a first valve position that sets a first refrigerant flow rate through the heat exchanger and a second valve position that sets a second refrigerant flow rate through the heat exchanger. The method includes controlling, with the controller, operation of a solenoid to actuate the valve at the operating frequency.

Abstract: A battery cooling plate includes a first plate and a second plate that are joined together at their respective edges, and are spaced apart to define a coolant volume therebetween. Turbulating inserts can be arranged side-by-side within the coolant volume and multiple rods can extend through the turbulating inserts to at least partially define flow barriers between coolant flow channels. A fluid manifold for the battery cooling plate includes a non-planar wall that extends along a length-wise direction of the fluid manifold to separate a fluid volume into a first portion and a second portion. A series of apertures are arranged along the length-wise direction and successive ones of the apertures are fluidly connected to the first portion and to the second portion in alternating sequence.

Abstract: A battery cooling plate includes a first plate and a second plate that are joined together at their respective edges, and are spaced apart to define a coolant volume therebetween. Turbulating inserts can be arranged side-by-side within the coolant volume and multiple rods can extend through the turbulating inserts to at least partially define flow barriers between coolant flow channels. A fluid manifold for the battery cooling plate includes a non-planar wall that extends along a length-wise direction of the fluid manifold to separate a fluid volume into a first portion and a second portion. A series of apertures are arranged along the length-wise direction and successive ones of the apertures are fluidly connected to the first portion and to the second portion in alternating sequence.

Abstract: Systems and methods for disrupting a flow of refrigerant within a heat exchanger assembly. One embodiment provides a method that includes receiving, with a controller, a first signal from a first sensor, the first signal indicative of a pressure of the refrigerant flowing through the heat exchanger. The method includes setting, with the controller, an operating frequency of a valve based on the first signal. The operating frequency includes a rate at which the valve actuates between a first valve position that sets a first refrigerant flow rate through the heat exchanger and a second valve position that sets a second refrigerant flow rate through the heat exchanger. The method includes controlling, with the controller, operation of a solenoid to actuate the valve at the operating frequency.

Abstract: A plate assembly for a heat exchanger includes a first plate, a second plate, and an intermediate plate arranged between the first and second plates. The intermediate plate is joined to the first and second plates at peripheral edges to create a sealed periphery of the plate assembly. Corrugations of the intermediate plate provide crests and troughs that are in contact with inwardly facing surfaces of the first and second plates. The plate assembly can be configured as a battery cooling plate heat exchanger to transfer heat from a battery to fluid flowing through the plate assembly.

Abstract: A battery cooling plate includes at least one planar heat transfer surface that is bounded by four edges. A coolant inlet port and a coolant outlet port are both arranged along a first one of the edges, and a coolant flow path extends through the battery cooling plate adjacent to the at least one planar heat transfer surface between the coolant inlet port and the coolant outlet port. The coolant flow path includes a first portion that extends along the entire length of a second, third, and fourth edge of the at least one planar heat transfer surface. The coolant flow path further includes a second portion that is arranged downstream of the first portion. The second portion of the coolant flow path is separated from the second, third, and fourth edges of the planar heat transfer surface by the first portion of the coolant flow path.

Abstract: A battery cooling plate includes a first plate and a second plate that are joined together at their respective edges, and are spaced apart to define a coolant volume therebetween. Turbulating inserts can be arranged side-by-side within the coolant volume and multiple rods can extend through the turbulating inserts to at least partially define flow barriers between coolant flow channels. A fluid manifold for the battery cooling plate includes a non-planar wall that extends along a length-wise direction of the fluid manifold to separate a fluid volume into a first portion and a second portion. A series of apertures are arranged along the length-wise direction and successive ones of the apertures are fluidly connected to the first portion and to the second portion in alternating sequence.

Abstract: A plate assembly for a heat exchanger includes a first plate, a second plate, and an intermediate plate arranged between the first and second plates. The intermediate plate is joined to the first and second plates at peripheral edges to create a sealed periphery of the plate assembly. Corrugations of the intermediate plate provide crests and troughs that are in contact with inwardly facing surfaces of the first and second plates. The plate assembly can be configured as a battery cooling plate heat exchanger to transfer heat from a battery to fluid flowing through the plate assembly.

Abstract: A liquid to refrigerant heat exchanger is provided having a stack of nested plates with fluid flow passages defined between the plates. The stack includes a condenser portion and a subcooler portion. A base plate at a bottom end of the stack has a refrigerant outlet port and a receiver bottle joined to it. A receiver flow path extends through a structural connection joining the receiver bottle to the base plate to allow for fluid flow between an internal volume of the receiver bottle and the condenser portion. Another receiver flow path extends through another structural connection to allow for fluid flow between an internal volume of the receiver bottle and the subcooler portion.

Abstract: A charge air cooler includes a first, second, and third heat exchange sections. In the first heat exchange section, heat is transferred from a first flow of liquid coolant to a refrigerant in order to cool the first flow of liquid coolant from a first temperature to a second temperature. In the second heat exchange section, heat is transferred from a flow of charge air to a second flow of liquid coolant in order to cool the flow of charge air from a third temperature to a fourth temperature. In the third heat exchange section, heat is transferred from the flow of charge air to the first flow of liquid coolant in order to cool the flow of charge air from the fourth temperature to a fifth temperature, the fifth temperature being less than the first temperature.

Abstract: A charge air cooler includes a first, second, and third heat exchange sections. In the first heat exchange section, heat is transferred from a first flow of liquid coolant to a refrigerant in order to cool the first flow of liquid coolant from a first temperature to a second temperature. In the second heat exchange section, heat is transferred from a flow of charge air to a second flow of liquid coolant in order to cool the flow of charge air from a third temperature to a fourth temperature. In the third heat exchange section, heat is transferred from the flow of charge air to the first flow of liquid coolant in order to cool the flow of charge air from the fourth temperature to a fifth temperature, the fifth temperature being less than the first temperature.

Abstract: A liquid to refrigerant heat exchanger is provided having a stack of nested plates with fluid flow passages defined between the plates. The stack includes a condenser portion and a subcooler portion. A base plate at a bottom end of the stack has a refrigerant outlet port and a receiver bottle joined to it. A receiver flow path extends through a structural connection joining the receiver bottle to the base plate to allow for fluid flow between an internal volume of the receiver bottle and the condenser portion. Another receiver flow path extends through another structural connection to allow for fluid flow between an internal volume of the receiver bottle and the subcooler portion.