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 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: 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 has a core comprised of at least one core section defined by a plate stack comprising a plurality of core plates, each core plate having a plurality of spaced apart, raised openings surrounded by a flat area. The raised openings of adjacent plates are sealed together to define a plurality of tubular structures. Top and bottom manifolds are sealed to the top and bottom of the core, with continuous top and bottom end plates providing structurally rigid connections between multiple core sections of the heat exchanger. The heat exchanger may have numerous configurations, including stepped core, curved core, angled core, and/or a core having multiple sections of the same or different length, while minimizing the number of unique parts and/or parts of complex shape.

Abstract: A heat exchanger has at least one plate pair comprising first and second plates with a fluid flow passage defined between the first plate and second plates. The inlet opening and the outlet opening in each plate pair are proximate to a first end and an elongate flow barrier separates the fluid flow passage into inlet and outlet portions, wherein a gap through and the flow barrier is provided proximate to the second end of each plate pair. A flow obstruction is located in the gap of each plate pair, the flow obstruction having first and second arcuate sides and being spaced from the terminal end of the flow barrier. The flow obstruction is substantially crescent-shaped, such that a middle portion of the flow obstruction is wider than the opposed ends.

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 apparatus containing a heat exchanger and a thermally actuated bypass valve is described. The heat exchanger has a plurality of plates defining a first, a second and a bypass channels. A first fluid inlet manifold is in fluid communication with the first and the bypass channels. The bypass valve is positioned in the first fluid inlet manifold, and contains a sleeve having a first slot and a second slot, that permit fluid flow from a first fluid inlet to the bypass channel and to the first fluid inlet manifold, respectively. A drum is positioned within the sleeve and is movable from a first position to a second position. The drum has an aperture permitting first fluid flow to the first slot in the first position and to the second slot in the second position. An actuator engages the drum and actuates it to move from the first position to the second position.

Abstract: A heat transfer surface for a heat exchanger has a corrugated member having parallel spaced apart ridges and planar fin surfaces extending the ridges. Tabs are formed in the planar fin surfaces for forming counter-rotating vortices in the fluid flowing over the heat transfer surface, the tabs being lifted out of the surface of the planar fin surface and extending into or nesting within the openings formed by the corresponding tabs in the adjacent planar fin surface so as to achieve high fin density.

Abstract: A multi-pass heat exchanger is provided wherein the heat exchanger is comprised of a plurality of stacked heat exchange plates defining a plurality of alternating first and second fluid channels interconnecting respective pairs of manifolds. At least one of the manifolds in the pairs of manifolds is in the form of an annular manifold structure which divides the heat exchanger into at least a first part and a second part thereby forming at least a two-pass flow path. The annular manifold structure is provided by a generally tubular manifold insert having one end embedded within the manifold. A first annular manifold flow passage communicates with one of the sets of fluid channels in the first part of the heat exchanger and a second, central manifold flow passage communicates with the corresponding set of fluid channels in the second part 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: An integrated gas management device (GMD) for a fuel cell comprises a gas-to-gas humidifier for transferring water from a second gas to a first gas; a heat exchanger attached to a first end of the humidifier core for cooling the first gas; and/or a water separator attached to a second end of the humidifier core for removing liquid water from the second gas. The GMD may optionally comprise a thermal isolation plate between the heat exchanger and the first end of the humidifier core. The GMD further comprises a bypass line to allow the first gas to bypass the humidifier. The first gas may comprise cathode charge air and the second gas may comprise cathode exhaust.

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 heat exchanger has a core comprised of at least one core section defined by a plate stack comprising a plurality of core plates, each core plate having a plurality of spaced apart, raised openings surrounded by a flat area. The raised openings of adjacent plates are sealed together to define a plurality of tubular structures. Top and bottom manifolds are sealed to the top and bottom of the core, with continuous top and bottom end plates providing structurally rigid connections between multiple core sections of the heat exchanger. The heat exchanger may have numerous configurations, including stepped core, curved core, angled core, and/or a core having multiple sections of the same or different length, while minimizing the number of unique parts and/or parts of complex shape.

Abstract: A heat exchanger comprises an end mounting arrangement including a mounting bracket having a first portion for attachment to a support structure and a second portion attached to the heat exchanger. A projection rigidly attached to the end of the heat exchanger is resiliently received in an aperture in the second portion of the mounting bracket. The projection may comprise a pin extending from a plate pair of the heat exchanger, and one end of the pin may be secured between the plates of the plate pair. The mounting bracket may be metal with a resilient element such as a rubber grommet provided in each aperture, or the bracket may comprise plastic in which case a grommet may not be required.

Abstract: A heat exchanger has a core comprising flat tubes with corrugated fins provided in spaces between tubes. An end mounting arrangement includes a mounting bracket for attachment to a housing. A fin support structure comprises a plurality of support walls and a plurality of axial walls, wherein each of the support walls is integrally joined to at least one of the axial walls, each of the support walls is in contact with the endmost corrugation of one of the fins, and each of the axial walls is in contact with one of the plate pairs. The fin support structure may have a corrugated structure, and is mounted at the end of the core at which the mounting bracket is provided, so as to support and minimize damage to the corrugated fins caused by bypass air flowing between the mounting bracket and the core.

Abstract: A heat exchanger apparatus containing a heat exchanger and a thermally actuated bypass valve is described. The heat exchanger has a plurality of plates defining a first, a second and a bypass channels. A first fluid inlet manifold is in fluid communication with the first and the bypass channels. The bypass valve is positioned in the first fluid inlet manifold, and contains a sleeve having a first slot and a second slot, that permit fluid flow from a first fluid inlet to the bypass channel and to the first fluid inlet manifold, respectively. A drum is positioned within the sleeve and is movable from a first position to a second position. The drum has an aperture permitting first fluid flow to the first slot in the first position and to the second slot in the second position. An actuator engages the drum and actuates it to move from the first position to the second position.

Abstract: A heat exchanger apparatus containing a heat exchanger, a fitting at the fluid inlet and a thermally actuated bypass valve positioned in a fluid inlet manifold of the heat exchanger. The valve contains a sleeve having first and second slots, that permit fluid flow from a fluid inlet to a bypass or fluid inlet manifold. A drum positioned within the sleeve is movable from a first to a second position, and has an aperture that permits fluid flow to the first or second slot. An actuator engages the drum and actuates it to move from the first to the second position. The sleeve further contains a lip positioned between the fitting and a bypass channel cover plate for affixing the sleeve in position.

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 multi-pass heat exchanger is provided wherein the heat exchanger is comprised of a plurality of stacked heat exchange plates defining a plurality of alternating first and second fluid channels interconnecting respective pairs of manifolds. At least one of the manifolds in the pairs of manifolds is in the form of an annular manifold structure which divides the heat exchanger into at least a first part and a second part thereby forming at least a two-pass flow path. The annular manifold structure is provided by a generally tubular manifold insert having one end embedded within the manifold. A first annular manifold flow passage communicates with one of the sets of fluid channels in the first part of the heat exchanger and a second, central manifold flow passage communicates with the corresponding set of fluid channels in the second part of the heat exchanger.

Abstract: A battery cell heat exchanger formed by a pair of mating plates that together form an internal tubular flow passage. The tubular flow passage is generally in the form of a serpentine flow passage extending between an inlet end and an outlet end and having generally parallel flow passage portions interconnected by generally U-shaped flow passage portions. The flow passage provides a graded heat transfer surface within each generally parallel flow passage portion and/or a variable channel width associated with each flow passage portion to provide improved temperature uniformity across the surface of the heat exchanger. The graded heat transfer surface may be in the form of progressively increasing the surface area associated with the individual flow passage portions with heat transfer enhancement features or surfaces arranged within the flow passage portions. The channel width and/or height may also be varied so as to progressively decrease for each flow passage portion.