Dana Canada Corporation

Long Manufacturing Ltd.

Kenneth M A Abels

Benjamin A Kenney

Doug Vanderwees

Michael A Martin

Lee M Kinder

John G Burgers

Colin Arthur Shore

Garreth D G Graves

Andrew J M Buckrell

Brian Edward Cheadle

Michael E Davies

Johny G Burgers

Sebastien R Gauguier

Alan K Wu

Ihab Edward Gerges

Farbod Vakilimoghaddam

Meinrad K A Machler

Christopher Lynn Flowers

Jiang Feng Yu

Andrei Catuneanu

Eric J Schouten

Robert Hance Brown

Nikola Vucenic

Meinrad K A Maehler

Alan Wu

A heat exchanger includes a fluid flow passage with a wavy fin turbulizer. The turbulizer includes sidewalls extending lengthwise along a fluid flow direction between its first and second ends, and the sidewalls are spaced apart across the width of the turbulizer. Each flow channel of the turbulizer is defined between two adjacent sidewalls. Each sidewall has a smoothly and continuously curved profile with repeating wave forms being defined along the length of the turbulizer. The continuously curved profile of the sidewalls is defined by a non-circular shape, such as elliptical, sinusoidal, parabolic and hyperbolic shapes. The radius of curvature changes constantly and reaches a maximum at or near the inflection point between adjacent crests and troughs of the profile, to provide improved particle pass-through, lower pressure drop, and enhanced plateability of internal surfaces.

Compact heat exchanger with wavy fin turbulizer

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.

Modular heat exchangers for battery thermal modulation

A heat exchanger assembly includes a cooling plate with at least one outer heat transfer surface adapted for thermal contact with one or more heat-generating substrates. A fluid flow path extends from an inlet port to an outlet port, with a plurality of cooling zones spaced apart along the fluid flow path, each cooling zone including a heat transfer element such as a corrugated fin sheet in contact with the inner surface of the first plate wall. Manifold spaces are defined proximate to the inlet and outlet ports, and between adjacent cooling zones. One or more bypass flow passages are provided between upstream and downstream ends of at least one cooling zone, to divert a portion of the heat transfer fluid from flowing through the cooling zone. The volume of fluid flow bypassing one or more cooling zones is calibrated to improve temperature uniformity of the heat-generating substrates.

High-performance heat exchanger with calibrated bypass

A heat exchanger for thermal management of battery units made-up of a plurality of battery cells or battery cell containers housing one or more battery cells. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages. In some embodiments the heat exchanger has two pairs of inlet and outlet manifolds, providing a single-pass, counter-flow arrangement. In other embodiments the first and second fluid flow passages are interconnected by turn portions forming a U-flow, counter-flow heat exchanger.

Counter-flow heat exchanger for battery thermal management applications

A two-pass heat exchanger with calibrated bypass is disclosed for cooling heat-generating substrates and/or for heating a heat transfer fluid. The heat exchanger has first and second outer plate walls and an intermediate plate wall located between and spaced from the outer plate walls in the thickness dimension of the heat exchanger, and with inlet and outlet ports at the same end. An input flow passage is defined between the first outer plate wall and the intermediate plate wall, and a return flow passage is defined between the second outer plate wall and the intermediate plate wall. The first and second fluid flow passages are in a U-flow, stacked arrangement. At least one bypass opening extends through the intermediate plate wall between the input and return flow passages, and configured to permit a portion of the heat transfer fluid to bypass portions of the input and return flow passages.

Two-pass heat exchanger with calibrated bypass

Methods and systems are provided for heat exchangers including a first outer plate, a second outer plate, and an intermediate plate. The intermediate plate is positioned between the outer plates. Fluid flow passages are formed between the intermediate plate and each of the outer plates.

Three-layer heat exchanger with internal manifold for battery thermal management

A heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers housing one or more battery cells is disclosed. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages providing a counter-flow heat exchanger.

A battery cell heat exchanger having a pair of plates that together define a fluid passage having a first channel permitting fluid flow from a first end of the plate pair towards a second end of the plate pair, and a second channel permitting fluid flow from the second end towards the first end of the plate pair. The plate pair together defining a first conduit at the first end of the plate pair, the first conduit being in fluid communication with the first channel. One of the pair of plates having an aperture permitting fluid flow from the second channel to a duct, the duct coupled to the one of the pair of plates having the aperture and having a second conduit in fluid communication with the aperture; where the first conduit and the second conduit lie in the plane defined by the pair of plates.

Counterflow heat exchanger with side entry fittings

A stacked-plate heat exchanger for cooling a plurality of heat-generating electronic components arranged in a plurality of layers comprises a stack of flat tubes defining a plurality of parallel fluid flow passages, the tubes being separated by spaces for receiving the electronic components. One or more flow-restricting ribs is arranged within at least some of the fluid flow passages to partially block fluid flow between at least one the manifolds and the heat transfer area by reducing the height of the fluid flow passage outside the heat transfer area, along at least a portion of the width of the fluid flow passage, in order to improve the flow distribution of a heat transfer fluid between and within the fluid flow passages of the heat exchanger, and to minimize bypass flow at the outer edges of the fluid flow passage.

Heat exchanger for cooling multiple layers of electronic modules

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.

Heat exchanger having bypass seal with retention clip

A heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers is disclosed. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages providing a counter-flow heat exchanger. In some embodiments the heat exchanger has a two pairs of inlet and outlet manifolds, the heat exchanger providing a single-pass, counter-flow arrangement. In other embodiments the first and second fluid flow passages are interconnected by turn portions forming a U-flow, counter-flow heat exchanger.

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.

Growing community of inventors

Oakville, Canada

Kenneth M A Abels