Abstract: One exemplary embodiment including a battery cooling plate has discrete channels. In one exemplary embodiment each of the channels has a width ranging from about 1 mm to about 5 mm. In another exemplary embodiment the battery cooling plate includes a first cooling channel having a flow path generally in a U shape, and a plurality of other channels each having a generally U-shaped flow path, and wherein the other flow channels are in a nested position with respect to the first flow channel.

Abstract: An exemplary embodiment includes a method of sealing battery cooling plates.

Abstract: Exemplary embodiment include method of sealing battery cooling plates, and methods of assembling battery using battery cooling plate racks and a single component including multiple cooling plates an connection portions therebetween.

Abstract: A method for preparing a bipolar plate assembly for a fuel cell stack is provided. The method first includes the steps of providing a first unipolar plate having a first active area with a plurality of channels formed on a first inner surface thereof, and a second unipolar plate having a second active area with a plurality of lands formed on a second inner surface thereof. The first unipolar plate and the second unipolar plate are aligned to dispose the first active area adjacent the second active area. A first pressure is then applied to the first and second active areas to pre-nest the first active area and the second active area. The perimeters of the first and second unipolar plates are then joined. A clamping fixture and associated method for assembling the bipolar plate assembly is also provided.

Abstract: A container is disclosed including a plurality of seal blocks adapted to militate against the entry of a fluid into coolant channel headers formed in bipolar plates during a dip coating process, wherein the seal blocks are interconnected and include a fastening portion and a sealing portion, the sealing portion capable of being interchanged.

Abstract: One embodiment of the invention comprises a fuel cell bipolar plate comprising a substrate comprising a first face, a reactant gas flow field defined in the first face, the reactant gas flow field comprising a plurality of lands and channels, and a plurality of microgrooves formed in the first face.

Abstract: A non-functional fuel cell for a fuel cell stack includes a shim disposed between gas diffusion media, a bipolar plate at one end, and either a bipolar plate or a unipolar plate at the other end. The shim of the non-functional cell replaces the membrane electrode assembly (MEA) in a normal fuel cell located in the middle or the end of the fuel cell stack. The shim is coated with electrically conductive, corrosion-resistant protective coating. The shim may be cleaned prior to applying the protective coating to remove an oxide layer from the surface of the shim. The non-functional fuel cell may be included in the initial design of the fuel cell stack, or may be used to replace one or more damaged or inoperative fuel cells to increase the overall performance of the fuel cell stack.

Abstract: Bipolar plates in a fuel cell stack tend to experience lower operating temperatures near and at the ends of the stack, and these plates require lower coolant flow. But common stamping tooling can be used to make all of the plates for the stack when suitable coolant flow restrictors are stamped into each plate for lowest coolant flow. The flow restrictors are then trimmed (or their formation avoided) from those plates designated for higher coolant flow.

Abstract: A multiple pass, parallel tube heat exchanger with a collection header extending along the length of each of a first and second pass, is provided with a bypass tube which fluidly interconnects the downstream end of the collection header to a midpoint thereof, near the end of the first pass tubes and the beginning of the second pass tubes so as to enhance the flow distribution of two-phase refrigerant from the collection header to the second pass tubes. The distribution flow is further enhanced by the insertion of an eductor nozzle within the collection header, and with the inlet of the eductor nozzle being supplied by refrigerant flow from the condenser to thereby provide a motive flow of two-phase refrigerant in the loop which includes the latter half of the collection header and the bypass tubes.

Abstract: A method of manufacturing metal fins suitable for use in a heat exchanger which includes providing a coated patterned fin stock having a series of parallel stripes disposed longitudinally across the width of one surface of the fin stock. The stripe pattern is evenly spaced in the central portion of the fin stock, and staggered or more further spaced apart at the edges of said fin stock. The fin stock is passed through a series of forming dies to form or draw a plurality of tube receiving collared holes in the fin stock, followed by slitting or cutting the fin stock longitudinally to form a plurality of fin strips. The staggered spacing compensates for transverse movement of the fin stock during the drawing operation, and assures for accurate positioning of the collars between the fin stripes. The invention also includes the use of the fins in a high density coil design for use in a heat exchanger.

Abstract: A method of manufacturing metal fins suitable for use in a heat exchanger which includes providing a coated patterned fin stock having a series of parallel stripes disposed longitudinally across the width of one surface of the fin stock. The stripe pattern is evenly spaced in the central portion of the fin stock, and staggered or more further spaced apart at the edges of said fin stock. The fin stock is passed through a series of forming dies to form or draw a plurality of tube receiving collared holes in the fin stock, followed by slitting or cutting the fin stock longitudinally to form a plurality of fin strips. The staggered spacing compensates for transverse movement of the fin stock during the drawing operation, and assures for accurate positioning of the collars between the fin stripes. The invention also includes the use of the fins in a high density coil design for use in a heat exchanger.

Abstract: A method of manufacturing metal fins suitable for use in a heat exchanger which includes providing a coated patterned fin stock having a series of parallel stripes disposed longitudinally across the width of one surface of the fin stock. The stripe pattern is evenly spaced in the central portion of the fin stock, and staggered or more further spaced apart at the edges of said fin stock. The fin stock is passed through a series of forming dies to form or draw a plurality of tube receiving collared holes in the fin stock, followed by slitting or cutting the fin stock longitudinally to form a plurality of fin strips. The staggered spacing compensates for transverse movement of the fin stock during the drawing operation, and assures for accurate positioning of the collars between the fin stripes. The invention also includes the use of the fins in a high density coil design for use in a heat exchanger.

Abstract: A method of manufacturing metal fins suitable for use in a heat exchanger which includes providing a coated patterned fin stock having a series of parallel stripes disposed longitudinally across the width of one surface of the fin stock. The stripe pattern is evenly spaced in the central portion of the fin stock, and staggered or more further spaced apart at the edges of said fin stock. The fin stock is passed through a series of forming dies to form or draw a plurality of tube receiving collared holes in the fin stock, followed by slitting or cutting the fin stock longitudinally to form a plurality of fin strips. The staggered spacing compensates for transverse movement of the fin stock during the drawing operation, and assures for accurate positioning of the collars between the fin stripes. The invention also includes the use of the fins in a high density coil design for use in a heat exchanger.

Abstract: A heat transfer tube (10) for use in an application, such as a shell and tube type air conditioning system condenser, in which a fluid flowing through the heat exchanger external to the tubes condenses by transfer of heat to a cooling fluid flowing through the tubes. The tube has at least one fin convolution (20) extending helically around its external surface (13). A pattern of notches (30) extends at an oblique angle (&agr;) across the fin convolutions at intervals about the circumference of the tube. There is a spike (22) between each pair of adjacent notches. The fin convolution, notches and spikes are formed in the tube by rolling the wall of the tube between a mandrel and, first, a gang of finning disks (63) and, second, a notching wheel (66). Because, during the manufacture of the tube, of the interaction of the rotating and advancing tube and the notching wheel, the angle (&bgr;) of inclination of the axis of the tip of the spike is oblique with respect to the notch angle.

Abstract: A method of manufacturing a heat transfer tube (10) having an external surface that is configured for enhanced heat transfer performance in both refrigerant evaporating and condensing applications. The tube is suitable for use in, for example, shell and tube type air conditioning condensers, flooded evaporators, falling film evaporator, or a combination of flooded and falling film evaporator. The tube has at least one fin convolution (20) extending helically around its external surface (13). A pattern of notches (30) extends at an oblique angle (.alpha.) across the fin convolutions at intervals about the circumference of the tube. There is a split spike (22) having two distal tips (23) between each pair of adjacent notches. The fin convolution, notches and split spikes are formed in the tube by rolling the wall of the tube between a mandrel and, first, a gang of finning disks (63), second, a notching wheel (66) and third, a splitter wheel (67).

Abstract: An evaporator heat transfer tube (10) for use in a heat exchanger where heat is transferred between a fluid flowing through the tube and a fluid flowing around the exterior of the tube and where the fluid external to the tube boils during the heat exchange process. The tube has a plurality of helical fins (20) extending around its external surface (13). A pattern of notches (30) extends at an oblique angle (.alpha.) across the fins at intervals about the circumference of the tube. A spike (22) having a flattened distal tip (23) is formed between each pair of adjacent notches. The maximum width (W.sub.t) of the spike at its tip is greater than the width (W.sub.t) of the base portion of the fin and is of a width sufficient to overlap with and contact the distal tips of spikes in adjacent fins on both sides thereof, thus forming reentrant cavities between the adjacent fins and under the overlapping tips.

Abstract: An apparatus for expanding the tubes in a heat exchanger of the plate fin and tube type. The expander is of the type that expands the tubes by driving a "bullet" through the tube with the bullet being attached to and driven by an expander or bullet rod. The apparatus has a sensor positioned so as to be able to measure the compressive force on the expander rod. The output of the sensor is proportional to the force exerted on the rod and can be used to provide an alarm or safety shutdown of the apparatus upon the sensing of excessive force on the expander rod. The sensor output can also be used for quality and process control.

Abstract: An evaporator heat transfer tube (10) for use in a heat exchanger where heat is transferred between a fluid flowing through the tube and a fluid flowing around the exterior of the tube and where the fluid external to the tube boils during the heat exchange process. The tube has a plurality of helical fins (20) extending around its external surface (13). A pattern of notches (30) extends at an oblique angle (.alpha.) across the fins at intervals about the circumference of the tube. A spike (22) having a flattened distal tip (23) is formed between each pair of adjacent notches. The maximum width (W.sub.t) of the spike at its tip is greater than the width (W.sub.r) of the base portion of the fin and is of a width sufficient to overlap with and contact the distal tips of spikes in adjacent fins on both sides thereof, thus forming reentrant cavities between the adjacent fins and under the overlapping tips.

Abstract: A tube for use in a heat exchanger where heat is transferred between a fluid flowing through the tube and a fluid flowing around the exterior of the tube and where the fluid external to the tube boils during the heat exchange process. The tube has one or more external fin convolutions extending from its external surface. At intervals along each side surface of the fin convolutions there are shoulder notches extending from the fin side surfaces. The groove space between adjacent fin convolutions has raised teeth located circumferentially at intervals. The fin convolutions do not extend perpendicularly from the tube surface but are inclined, with one convolution overlying an adjacent groove but not touching its adjacent neighbor fin convolution to form a re-entrant boiling cavity with an opening gap. In one embodiment, the opening gap extends completely around the circumference of the tube.