Abstract: A battery heat exchanger for a vehicle may include a first outer plate; a second outer plate positioned in parallel with the first outer plate; a fluid inlet; a fluid outlet; and an intermediate plate positioned between the first outer plate and the second outer plate, the intermediate plate comprising a rib to separate an inlet portion from an outlet portion of the heat exchanger; and a plurality of corrugations with openings for thermal exchange medium fluid flow, where the corrugations have different orientations and lengths.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: Methods and systems are provided for a heat exchanger. In one example, the heat exchanger may dissipate energy generated by a battery module and may include a first plate and a second plate arranged in opposed facing relation to one another. A plurality of flow passages may be formed between the first and second plates, the plurality of flow passages including at least one multipass fluid flow passage with at least three longitudinally-extending legs.

Abstract: A cold plate heat exchanger for battery thermal management has first and second plates defining a plurality of fluid flow passages, with inlet and outlet ports proximate to a first end thereof. Each fluid flow passage has first and second ends communicating with respective inlet and outlet ports. One or more portions of each fluid flow passage are immediately adjacent to and in close proximity to a portion of another fluid flow passage or channel, such that heat energy will be transferred by conduction through the first and second plates between the fluid flow passages or channels, thereby providing enhanced heat transfer. The fluid flow passages or channels may be separated by a distance which is less than a width of one of the fluid flow passages or channels, and may be separated by a single rib which partially defines each of the fluid flow passages or channels.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A cold plate heat exchanger for battery thermal management has first and second plates defining a plurality of fluid flow passages, with inlet and outlet ports proximate to a first end thereof. Each fluid flow passage has first and second ends communicating with respective inlet and outlet ports. One or more portions of each fluid flow passage are immediately adjacent to and in close proximity to a portion of another fluid flow passage or channel, such that heat energy will be transferred by conduction through the first and second plates between the fluid flow passages or channels, thereby providing enhanced heat transfer. The fluid flow passages or channels may be separated by a distance which is less than a width of one of the fluid flow passages or channels, and may be separated by a single rib which partially defines each of the fluid flow passages or channels.

Abstract: A heat exchanger having a core defining a plurality of first fluid flow passages and a plurality of second fluid flow passages arranged in alternating order, and a housing enclosing the core. The housing has a top wall arranged opposite to the top of the core, and a bottom wall arranged opposite to the bottom of the core. A plurality of connecting structures which together provide a rigid connection between the core and the housing, wherein each of the connecting structures provides a connection between the top of the core and the top wall of the housing, or between the bottom of the core and the bottom wall of the housing. Wherein each of the connecting structures has a first connecting element and a second connecting element. The first connecting element is associated with the core and the second connecting element is associated with the housing.

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: Methods and systems are provided for a heat exchanger. In one example, the heat exchanger may dissipate energy generated by a battery module and may include a first plate and a second plate arranged in opposed facing relation to one another. A plurality of flow passages may be formed between the first and second plates, the plurality of flow passages including at least one multipass fluid flow passage with at least three longitudinally-extending legs.

Abstract: A modular heat exchanger for battery thermal management having a plurality of similarly constructed heat exchange elements affixed to a cover plate and fluidly coupled with one another via a single external manifold structure that functions as both an inlet manifold and an outlet manifold for each of the heat exchange elements. Rigidity is improved with alternating tabs or overlapping tabs between adjacent elements, and/or side edges between adjacent elements having cutouts for receiving stiffening ribs formed in the cover plate. The external manifold structure provides additional stiffening for the interconnected heat exchange elements.

Abstract: A heat exchanger comprises a stack of flat tubes defining first and second fluid flow passages, and a housing having side covers over the sides of the core, and being spaced from the sides of the core. The heat exchanger further comprises a bypass seal comprising a pair of side seals and a pair of clip members. The side seals are received between the sides of the core and the housing. Each side seal has an inner surface engaging the first side of the core and an outer surface engaging the first side wall of the housing. Each clip member has a middle portion to which a side seal is connected, as well as opposed first and second end portions which engage inwardly extending surfaces of the core.

Abstract: A heat exchanger having a core defining a plurality of first fluid flow passages and a plurality of second fluid flow passages arranged in alternating order, and a housing enclosing the core. The housing has a top wall arranged opposite to the top of the core, and a bottom wall arranged opposite to the bottom of the core. A plurality of connecting structures which together provide a rigid connection between the core and the housing, wherein each of the connecting structures provides a connection between the top of the core and the top wall of the housing, or between the bottom of the core and the bottom wall of the housing. Wherein each of the connecting structures has a first connecting element and a second connecting element. The first connecting element is associated with the core and the second connecting element is associated with the housing.

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 gas/liquid heat exchanger for cooling a hot gas has a plastic housing at least partly surrounding a metal core. The housing has separately formed inlet and outlet segments which may be formed from plastic materials having different heat resistance, and which are joined together along a sealed joint. One or both of the inlet and outlet segments are provided with bypass blocking element to at least partially blocks any gaps between the irregularly shaped sides of the core and the sides of the housing. Where the sides of the core include indentations, the bypass blocking elements may comprise a comb structure having fingers extending into the indentations. The housing is constructed to permit the core to be slidingly received into one or both of the inlet segment and the outlet segment of the housing.

Abstract: A heat exchanger comprises a stack of flat tubes defining first and second fluid flow passages, and a housing having side covers over the sides of the core, and being spaced from the sides of the core. The heat exchanger further comprises a bypass seal comprising a pair of side seals and a pair of clip members. The side seals are received between the sides of the core and the housing. Each side seal has an inner surface engaging the first side of the core and an outer surface engaging the first side wall of the housing. Each clip member has a middle portion to which a side seal is connected, as well as opposed first and second end portions which engage inwardly extending surfaces of the core.

Abstract: A gas/liquid heat exchanger comprises a stack of flat tubes, defining liquid flow passages. Spaces between the flat tubes define gas flow passages, with the sides of the core having an irregular comb-like arrangement. The heat exchanger further comprises a housing having side covers over the sides of the core, and being spaced from the sides of the core. The core has at least one portion of reduced width, so as to provide channels extending throughout the height of the core. The heat exchanger further comprises a pair of side seals at least partly received in the gap between the side cover of the housing and the core, and more particularly in the channels along the sides of the core. The side seal extends throughout the height of the core and has a thickness which is greater than that of the gap.

Abstract: An elongate heat exchanger for cooling hot gas includes an arrangement for reducing thermal stresses when mounted in a housing. A pair of planar extensions project from opposite sides of the core. A mounting bracket has a central portion adapted to extend across the top of the core, and a pair of edge portions projecting outwardly from the central portion. The edge portions are substantially parallel to the planar extensions, and each has a top layer at least partially covering one of the planar extensions, wherein each of the edge portions is adapted to be secured to the housing, for example by a bolt. Each planar extension may be slidably received in a slot between the top and bottom layers of the edge portion, or may be slidably received between the top layer and the housing, to permit longitudinal thermal expansion of the core.

Abstract: A gas/liquid heat exchanger for cooling a hot gas has a plastic housing at least partly surrounding a metal core. The housing has separately formed inlet and outlet segments which may be formed from plastic materials having different heat resistance, and which are joined together along a sealed joint. One or both of the inlet and outlet segments are provided with bypass blocking element to at least partially blocks any gaps between the irregularly shaped sides of the core and the sides of the housing. Where the sides of the core include indentations, the bypass blocking elements may comprise a comb structure having fingers extending into the indentations. The housing is constructed to permit the core to be slidingly received into one or both of the inlet segment and the outlet segment of the housing.