Multi-purpose heat exchanger sheet

Abstract

A heat exchanger includes a first plate, a second plate and a sheet positioned between the first plate and the second plate. A sheet first face sheet abuts a first plate inner surface. A sheet perimeter portion abuts a second plate perimeter portion. A second plate inward portion is spaced from a first plate inward portion. The sheet perimeter portion is connected to the first plate perimeter portion and to the second plate perimeter portion such that a coolant flow path is formed between the first plate and the second plate. The sheet inward portion includes at least one protrusion having a first end coupled to the sheet and a second free end partially detached from the sheet. The at least one protrusion extends from the first plate to the second plate such that the first end abuts the first plate and the second free end abuts the second plate.

Description

MULTI-PURPOSE HEAT EXCHANGER SHEETBACKGROUND

[0001] The present disclosure relates to heat exchangers.

[0002] In one aspect, the disclosure provides a heat exchanger insert configuration that maintains proper spacing between opposing plates while minimizing the pressure drop across the heat exchanger.SUMMARY

[0003] In some embodiments, a heat exchanger includes a first plate, a second plate and a sheet positioned between the first plate and the second plate.

[0004] In some embodiments, the first plate has a first inner surface and a first outer surface opposite the first inner surface. The first plate additionally has a first inward portion generally surrounded by a first perimeter portion.

[0005] In some embodiments, the second plate also has a second inner surface and a second outer surface opposite the second inner surface. The second plate also has a second inward portion generally surrounded by a second perimeter portion.

[0006] In some embodiments, a coolant flow path extends between a first aperture and a second aperture. The first aperture being defined by one of the first plate and the second plate, and the second aperture being defined by one of the first plate and the second plate.

[0007] In some embodiments, the sheet includes a third aperture proximate the first aperture to permit coolant flow through the second sheet, and a fourth aperture near the second aperture. The sheet has a sheet inward portion generally surrounded by a sheet perimeter portion. The sheet includes a first face and a second face. The first face of the sheet abuts the first inner surface of the first plate, and the sheet perimeter portion of the second face of the sheet abuts the second inner surface proximate the second perimeter portion. The second inward portion is spaced from the first inward portion by a passage height. The sheet perimeter portion is sealingly coupled to the first perimeter portion and to the second perimeter portion such that acoolant flow path is formed between the first plate and the second plate. The coolant flow path extends between the first aperture and the second aperture.

[0008] In some embodiments, the sheet inward portion includes at least one protrusion having a first end coupled to the sheet and a second free end at least partially detached from the sheet. The at least one protrusion has a protrusion height extending from the first plate to the second plate such that the first end abuts the first plate and the second free end abuts the second plate.

[0009] In some embodiments, the at least one protrusion further includes a middle portion between the first end and the second free end, such that the first end extends generally parallel to the first plate, the middle portion extends generally away from the first plate, and the second free end extends generally parallel to the second plate.

[0010] In some embodiments, the at least one protrusion is formed by bending, such that a first bend is positioned between the first end and the middle portion, and a second bend is positioned between the middle portion and the second free end.

[0011] In some embodiments, the at least one protrusion includes a first group of protrusions and a second group of protrusions, oriented parallel to the first group of protrusions. The first group of protrusions are oriented such that the second free end is positioned closer to the third aperture than the first end. The second group of protrusions are oriented such that the first end is positioned closer to the third aperture than the second free end. The protrusions of the first group of protrusions alternate with the protrusions of the second group of protrusions.

[0012] In some embodiments, each protrusion is positioned along the coolant flow path and configured to direct a flow of coolant along the coolant flow path, the coolant flow path having a non-linear circuitous shape.

[0013] In some embodiments, each protrusion is oriented such that the first end, the middle portion and the second free end all extend generally parallel to the coolant flow path.

[0014] In some embodiments, the protrusions are oriented such that the second free ends of the first group of protrusions are each adjacent at least one of the second free ends of the second group of protrusions.

[0015] In some embodiments, the alternating protrusions form a coolant flow channel along the coolant flow path.

[0016] In some embodiments, the protrusions further include a third group of protrusions and a fourth group of protrusions, oriented parallel to the third group of protrusions. The third group of protrusions are oriented such that the second free end is positioned closer to the third aperture than the first end. The fourth group of protrusions are oriented such that the first end is positioned closer to the third aperture than the second free end. The protrusions of the third group of protrusions alternate with the protrusions of the fourth group of protrusions.

[0017] In some embodiments, the alternating protrusions form a first coolant flow channel along the coolant flow path, and the third and fourth groups of protrusions form a second coolant flow channel along the coolant flow path. The second flow channel extends parallel to the first flow channel, and the second flow channel is positioned closer to the third aperture than the first flow channel.

[0018] In some embodiments, a fifth group of protrusions is included. The fifth group of protrusions are oriented at an acute angle with respect to the first group of protrusions.

[0019] In some embodiments, the sheet is fixedly coupled to the first plate and the second free ends are fixedly coupled to the second plate. The protrusions are configured to retain the second plate spaced from the first plate by the passage height.

[0020] In some embodiments, the at least one protrusion defines the third aperture, and the first end of the first protrusion includes a semi-circular shape.

[0021] In some embodiments, the at least one protrusion is semi dome-shaped extending from the semi-circular first end to the apex of the semi-dome. The second end of the first protrusion positioned at the apex and in abutment with the second plate.

[0022] In some embodiments, the at least one protrusion functions as a flow guide to direct coolant through the third aperture while reducing the pressure drop of fluid flowing through the third aperture.

[0023] In some embodiments, the at least one protrusion at least partially defines the fourth aperture.

[0024] In some embodiments, the at least one protrusion is configured to retain the first plate spaced the passage height from the second plate proximate the fourth aperture. In some embodiments, the at least one protrusion is formed by bending.

[0025] In some embodiments, a semi-circular protrusion partially encircles the fourth aperture proximate the at least one protrusion. The semi-circular protrusion is configured to guide flow of coolant through the fourth aperture.

[0026] In some embodiments, the at least one protrusion extends at an acute angle with respect to the first plate.

[0027] In some embodiments, the at least one protrusion at least partially defines the fourth aperture, and the second free end of the at least one protrusion forms a wave shape having a variable height above the first plate.

[0028] In some embodiments, an insert is positioned in the fourth aperture between the first plate and the second plate, and the at least one protrusion configured to inhibit flow of coolant around the insert.

[0029] In some embodiments, a retaining protrusion and an insert are included. The retaining protrusion at least partially defines the fourth aperture, and the retaining protrusion is configured to retain the insert between the first plate and the second plate.

[0030] In some embodiments, the protrusion inhibits flow around the turbulator.

[0031] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 is a perspective view of a heat exchanger according to some embodiments of the present invention.

[0033] FIG. 2 is another perspective view of the heat exchanger of FIG. 1.

[0034] FIG. 3 is an exploded view of the heat exchanger.

[0035] FIG. 4 is a perspective view of an internal sheet of the heat exchanger.

[0036] FIG. 5 is a cross section view taken along line 5-5 of FIG. 2.

[0037] FIG. 6 is a cross section view taken along line 6-6 of FIG. 2.

[0038] FIG. 7 is a close-up view of an outlet portion.

[0039] FIG. 8 is a close-up view of an inlet portion.

[0040] FIG. 9 is a cross section view taken along line 9-9 of FIG. 2.

[0041] FIG. 10 is a close-up view of a portion of a sheet shown in FIG. 8 with some elements removed for clarity.DETAILED DESCRIPTION

[0042] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

[0043] FIG. 1 illustrates a heat exchanger 10 including a first plate 12, a second plate 14 and a sheet 16 positioned between the first plate 12 and the second plate 14. The first plate 12 includes a first aperture 20 that permits coolant to flow through the first plate 12. In the illustrated embodiment, a first coupling 22 abuts the first plate 12 to connect the first aperture to an outside component (i.e., a coolant pump). The first plate 12 also includes a first inner surface24 and a first outer surface 26 opposite the first inner surface 24 (see FIG. 3). The first plate 12 also has a first inward portion 28 generally surrounded by a first perimeter portion 30. In some embodiments, the first aperture 20 can be defined by the second plate 14.

[0044] FIG. 2 illustrates the second plate 14 in greater detail. The second plate 14 includes a second aperture 40 that permits coolant to flow through the second plate 14. In the illustrated embodiment, a second coupling 42 abuts the second plate 14 to connect the second aperture 40 to an outside component (i.e., the coolant pump). The second plate 14 also has a second inner surface 44 and a second outer surface 46 opposite the second inner surface 44 (see FIG. 3). The second plate 14 has a second inward portion 48 generally surrounded by a second perimeter portion 50. In some embodiments, the second aperture 40 can be defined by the first plate 12.

[0045] FIGS. 3 and 4 illustrate the sheet 16 in greater detail. The sheet 16 defines a third aperture 56 and a fourth aperture 58. The third aperture 56 is positioned proximate the first aperture 20 to permit coolant flow through the first plate 12. The fourth aperture 58 is positioned near the second aperture 40. A coolant flow path extends between the first and third apertures 20, 56 and the second and fourth apertures 40, 58. In some embodiments, the second aperture 40 is an inlet aperture permitting coolant to flow into the coolant flow path. Likewise, in some embodiments, the first and third apertures 20, 56 are outlet apertures permitted coolant to flow out of the coolant flow path.

[0046] The sheet 16 includes a sheet inward portion 62, a sheet perimeter portion 64, a first face 66 and a second face 68 (see FIGS. 3-5). The sheet inward portion 62 is generally surrounded by the sheet perimeter portion 64.

[0047] With reference to FIGS. 3 and 5, the first face 66 of the sheet 16 abuts the first inner surface 24 of the first plate 12. The sheet perimeter portion 64 of the second face 68 of the sheet 16 abuts the second inner surface 44 of the second plate 14 proximate the second perimeter portion 50. The sheet perimeter portion 64 is sealingly coupled to the first perimeter portion 30 and to the second perimeter portion 50 to form the coolant flow path between the first plate 12 and the second plate 14. In some embodiments, one or more components, such as a braze sheet, are positioned between the sheet 16 and the first plate 12, and between the sheet and the second plate 14.

[0048] The illustrated first plate 12 is generally planar such that the first inward portion 28 and the first perimeter portion 30 lie in a first plane. The second perimeter portion 50 is spaced from the first plate 12 by a distance substantially equal to the thickness of the sheet 16 and any intervening brazing sheets. The second inward portion 48 is spaced from the first plate 12 by a height 72. The coolant flow path has a height corresponding to the height 72. In some embodiments, the first plate 12 is non-planar with the first inward portion 28 lying in a plane spaced from the first perimeter portion 30.

[0049] With reference to FIGS. 4 and 5, the illustrated sheet inward portion 62 includes a plurality of protrusions of varying shapes, sizes, and locations. A plurality of first protrusions 76 each include a first end 78 coupled to the sheet 16 and a second free end 80 partially detached from the sheet 16. The first ends 78 are positioned proximate the first plate 12 and extend generally parallel to the first plate 12. The second free ends 80 are positioned proximate the second plate 14 and extend parallel to the second plate 14. Each of the first protrusions 76 defines a protrusion height extending between the first plate 12 and the second plate 14, that corresponds to the height 72. In some embodiments, the first ends 78 are coupled to the second plate 14 (i.e., by brazing). In other embodiments, the first ends 78 are retained in abutment with the second plate 14 by the work hardening of the sheet 16 without any additional coupling agent.

[0050] The first protrusions 76 each include a middle portion 82 between the first end 78 and the second free end 80. The middle portions 82 extend generally away from the first plate 12 and toward the second plate 14. Each of the first protrusions 76 is formed by bending. A first bend is positioned between the first end 78 and the middle portion 82, and a second bend is positioned between the middle portion 82 and the second free end 80.

[0051] A plurality of second protrusions 86 each include a first end 88 coupled to the sheet 16 and a second free end 90 partially detached from the sheet 16. The first ends 88 are positioned proximate the first plate 12 and extend generally parallel to the first plate 12. The second free ends 90 are positioned proximate the second plate 14 and extend generally parallel to the second plate 14. Each of the second protrusions 86 defines a protrusion height extending between the first plate 12 and the second plate 14 that corresponds to the height 72. In some embodiments, the second free ends 90 are coupled to the second plate 14 (i.e., by brazing). Inother embodiments, the second free ends 88 are retained in abutment with the second plate 14 by the work hardening of the sheet 16 without any additional coupling agent.

[0052] The second protrusions 86 each include a middle portion 92 between the first end 88 and the second free end 90. The middle portions 92 extend generally away from the first plate 12 and toward the second plate 14. Each of the second protrusions 86 is formed by bending. A first bend is positioned between the first end 88 and the middle portion 92, and a second bend is positioned between the middle portion 92 and the second free end 90.

[0053] The first protrusions 76 are oriented such that the second free end 80 is positioned closer to the third aperture 56 than the first end 78. The second protrusions 86 are oriented such that the first end 88 is positioned closer to the third aperture 56 than the second free end 90.

[0054] In the illustrated embodiment, the first protrusions 76 alternate with and are oriented parallel to the second protrusions 86. The first and second protrusions 76, 86 are oriented such that the second free ends 80 of the first protrusions 76 are each adjacent at least one of the second free ends 90 of the second protrusions 86. The alternating protrusions 76, 86 form a plurality of coolant flow channels 96a, 96b, 96c along the coolant flow path. The coolant flow channels 96a, 96b and 96c extend generally parallel to one another. The coolant flow channel 96a is positioned closer to the third aperture 56 than the coolant flow channels 96b, 96c.

[0055] In other embodiments, the protrusions 76, 86 are positioned in different groupings and configurations. For example, the first protrusions 76 can be positioned adjacent other first protrusions 76 to form a first portion of a linear channel and the second protrusions 86 can be positioned adjacent other second protrusions 86 to form a second portion of the linear channel that is spaced from the first portion. In still other embodiments, different patterns can be formed by the protrusions 76, 86. For example, two first protrusions 76 can be positioned between second protrusions 86. Additionally, two second protrusions 86 can be positioned between first protrusions 76. Other configurations and groupings of the first and second protrusions 76, 86 can be utilized.

[0056] With reference to FIGS. 4 and 6, the sheet 16 also includes third protrusions 100 that include a first end 102, a second free end 104 and a middle portion 106. The first end 102 isproximate the first plate 12 and the second free end 104 is proximate the second plate 14. Some of the third protrusions 100 are oriented at an acute angle with respect to the first protrusions 76. Others of the third protrusions 100 are oriented at a right angle with respect to the first protrusions 76. The height of the third protrusions 100 corresponds to the height 72. The third protrusions 100 are similar to the first protrusions 76 except for the orientation with respect to the third aperture 56.

[0057] The sheet 16 further includes fourth protrusions 110 having a first end 112, a second free end 114 and a middle portion 116. The first end 112 is proximate the first plate 12 and the second free end 114 is proximate the second plate 14. Some of the fourth protrusions 110 are oriented at an acute angle with respect to the second protrusions 86. Others of the fourth protrusions 110 are oriented at a right angle with respect to the second protrusions 86. The height of the fourth protrusions 110 generally corresponds to the height 72. The fourth protrusions 110 are similar to the second protrusions 86 except for the orientation with respect to the third aperture 56.

[0058] The first, second, third and fourth protrusions 76, 86, 100, 110 cooperate to retain the second plate 14 spaced from the first plate 12 by the passage height. The first, second, third and fourth protrusions 76, 86, 100, 110 are each positioned along the coolant flow path and are configured to direct a flow of coolant along the coolant flow path. The illustrated coolant flow path has a non-linear circuitous shape. Each protrusion 76, 86, 100, 110 is oriented such that the first end 78, 88, 102, 112 the middle portion 82, 92, 106, 116 and the second free end 80, 90, 104, 114 all extend generally parallel to the coolant flow path.

[0059] The illustrated first and second protrusions 76, 86 are all shown in groups that define the coolant flow channels 96a, 96b, 96c. The illustrated third and fourth protrusions 100, 110 are positioned along the curved coolant flow path and are spaced apart from adjacent protrusions 100, 110 by variable distances. The specific locations and orientations of the first, second, third and fourth protrusions 76, 86, 100, 110 are given by way of example only. Other orientations and configurations of the first, second, third and fourth protrusions 76, 86, 100, 110 can be utilized to perform the function of retaining the second plate 14 spaced from the first plate 12 by the passage height.

[0060] With reference to FIG. 7, a fifth protrusion 120 at least partially defines the third aperture 56. The fifth protrusion 120 is semi done-shaped and includes a first end 122 with a semi-circular shape and a second end 124 which arch-shaped and forms an apex of the semidome. The first end 122 is positioned proximate the first plate 12 and the second end 124 is positioned proximate the second plate 14.

[0061] The fifth protrusion 120 functions as a flow guide to direct coolant through the third aperture 56 and toward the first aperture 20 while reducing the pressure drop of fluid flowing through the first and third apertures 20, 56. The fifth protrusion 120 also supports the first and second plates 12, 14 during the pressure and temperature change that often occur at the first and third apertures 20, 56.

[0062] With reference to FIG. 8, a sixth protrusion 130 is positioned proximate the second aperture 40 and at least partially defines the fourth aperture 58. The sixth protrusion 130 includes a first end 132, a second free end 134 and a middle portion 136, The first end 132 is proximate the first plate 12 and the second free end 134 is proximate the second plate 14. The sixth protrusion 130 has a height that generally corresponds to the height 72, such that the sixth protrusion 130 retains the spacing between the first plate 12 and the second plate 14 proximate the second aperture 40. The sixth protrusion 130 is formed by bending the sheet 16.

[0063] A seventh protrusion 140 is a semi-circular protrusion proximate the second aperture 40. The seventh protrusion 140 guides the flow of coolant from the second aperture 40 toward the fourth aperture 58. The seventh protrusion 140 has a height corresponding to the height 72. The seventh protrusion 140 strengthens the first and second plates 12, 14 proximate the second aperture 40 and reduces the pressure drop as the coolant passes through the second aperture 40.

[0064] As shown most clearly in FIGS. 3 and 4, three inserts 142 are positioned within the fourth aperture 58. While shown schematically, these inserts 142 can be turbulators or other elements that enhance the heat exchange between the coolant within the coolant flow path and the surrounding first and second plates 12, 14. Other sizes, types and configurations of inserts 142 can be utilized in other embodiments.

[0065] The inserts 142 define an insert height 144 (see FIG. 9). The distance between the first inward portion 28 of the first plate 12 and the second inward portion 48 of the second plate 14 proximate the fourth aperture 58 corresponds to the insert height 144. In the illustrated embodiment, the insert height is less that the height 72 because the distance between the first plate 12 and the second plate 14 adjacent the fourth aperture 58 is less than the height 72. In other embodiments, the insert height 144 is similar to the height 72. In still other embodiments, the insert height 144 is greater than the height 72.

[0066] With continued reference to FIGS. 3 and 4, an eighth protrusion 146 at least partially defines the fourth aperture 58. The illustrated embodiment includes three of the eighth protrusions 146 on one side of the fourth aperture 58 and three of the eighth protrusions 146 on the opposite side of the fourth aperture 58. Three inserts 142 are positioned between the opposing eighth protrusions 146 within the fourth aperture 58.

[0067] With reference to FIGS. 10, the eighth protrusion 146 includes a first end 148 proximate the first plate 12 and a second free end 150 that forms a wave shape. The second free end 150 has a variable height above the first plate 12. The second free end 150 includes lower portions 152 that abut or nearly abut the first plate 12 and upper portions 154 that abut the second plate 14. The upper portions 154 extend at an acute angle with respect to the first plate 12. The eighth protrusions 146 are positioned on opposite edges of the inserts 142 to inhibit flow of coolant around the inserts 142. In the illustrated embodiment, there are six (6) eighth protrusions 146 positioned around the fourth aperture 58. Other quantities of eighth protrusions 146 can be utilized in embodiments that include different quantities of inserts 142.

[0068] As shown most clearly in FIGS. 4 and 10, a ninth protrusion 160 at least partially defines the fourth aperture 58. The ninth protrusion 160 is a retaining protrusion that retains the inserts 142 at the desired position within the fourth aperture 58. In the illustrated embodiment, three (3) ninth protrusions 160 are positioned in the fourth aperture 58. Each of the ninth protrusions 160 are positioned on one side of the inserts 142. In other configurations, ninth protrusions 160 can be positioned on both sides of the inserts 142. Other sizes, shapes and configurations of retaining protrusions 160 can be utilized at least partially based upon the size, shape and configuration of the inserts 142 and the fourth aperture 58.

[0069] The protrusions disclosed herein accomplish several different functions. For example, the first, second, third and fourth protrusions 76, 86, 100, 110 retain the appropriate spacing between the first and second plates 12, 14 and guide flow of coolant through the coolant flow path. The fifth protrusion 120 strengthens the first and second plates 12, 14 proximate the first and third apertures 20, 56, guides coolant into the first aperture 20, and reduces the pressure drop at the first and third apertures 20, 56. The sixth and seventh protrusions 130, 140 strengthen the first and second plates 12, 14 proximate and the second and fourth apertures 40, 58 and reduce the pressure drop at the second and fourth apertures 40, 58. The eighth protrusions 146 inhibit undesirable bypass of coolant around one or more inserts 142. The ninth protrusions 160 retain one or more inserts 142 in place.

[0070] Since a majority of the sheet 16 is adjacent the first plate 12, the first plate 12 can be thinner than if the sheet 16 were omitted. As such, the sheet 16 does not require much if any additional material than a configuration with only first and second plates 12, 14.

[0071] The present application presents different embodiments of heat exchanger protrusion configurations that enhance heat exchanger performance while maintaining a low pressure drop relative to other protrusion configurations.

Claims

CLAIMSWhat is claimed is:

1. A heat exchanger compri sing : a first plate having a first inner surface and a first outer surface opposite the first inner surface, the first plate having a first inward portion generally surrounded by a first perimeter portion; a second plate having a second inner surface and a second outer surface opposite the second inner surface, the second plate having a second inward portion generally surrounded by a second perimeter portion; a coolant flow path extending between a first aperture and a second aperture, the first aperture being defined by one of the first plate and the second plate, and the second aperture being defined by one of the first plate and the second plate; and a sheet positioned between the first plate and the second plate, the sheet including a third aperture proximate the first aperture to permit coolant flow through the first sheet, and a fourth aperture near the second aperture, the sheet having a sheet inward portion generally surrounded by a sheet perimeter portion, the sheet including a first face and a second face, the first face of the sheet abutting the first inner surface of the first plate, the sheet perimeter portion of the second face of the sheet abutting the second inner surface proximate the second perimeter portion, the second inward portion spaced from the first inward portion by a passage height, the sheet perimeter portion sealingly coupled to the first perimeter portion and to the second perimeter portion such that a coolant flow path is formed between the first plate and the second plate, the coolant flow path extending between the first aperture and the second aperture, the sheet inward portion including at least one protrusion having a first end coupled to the sheet and a second free end partially detached from the sheet, the at least one protrusion having a protrusion height extending from the first plate to the second plate such that the first end abuts the first plate and the second free end abuts the second plate.

2. The heat exchanger of claim 1, wherein the at least one protrusion further includes a middle portion between the first end and the second free end, such that the first end extendsgenerally parallel to the first plate, the middle portion extends generally away from the first plate, and the second free end extends parallel to the second plate.

3. The heat exchanger of claim 1 or claim 2, wherein the at least one protrusion is formed by bending, such that a first bend is positioned between the first end and the middle portion, and a second bend is positioned between the middle portion and the second free end.

4. The heat exchanger of any of claims 1 to 3, wherein the at least one protrusion includes a first group of protrusions and a second group of protrusions, oriented parallel to the first group of protrusions, the first group of protrusions are oriented such that the second free end is positioned closer to the third aperture than the first end, the second group of protrusions are oriented such that the first end is positioned closer to the third aperture than the second free end, the protrusions of the first group of protrusions alternate with the protrusions of the second group of protrusions.

5. The heat exchanger of claim 4, wherein each protrusion is positioned along the coolant flow path and configured to direct a flow of coolant along the coolant flow path, the coolant flow path having a non-linear circuitous shape.

6. The heat exchanger of claim 4 or claim 5, wherein each protrusion is oriented such that the first end, the middle portion and the second free end all extend generally parallel to the coolant flow path.

7. The heat exchanger of any of claims 4 to 6, wherein the protrusions are oriented such that the second free ends of the first group of protrusions are each adjacent at least one of the second free ends of the second group of protrusions.

8. The heat exchanger of any of claims 4 to 7, wherein the alternating protrusions form a coolant flow channel along the coolant flow path.

9. The heat exchanger of any of claims 4 to 8, wherein the protrusions further include a third group of protrusions and a fourth group of protrusions, oriented parallel to the third group of protrusions, the third group of protrusions are oriented such that the second free end is positioned closer to the third aperture than the first end, the fourth group of protrusions areoriented such that the first end is positioned closer to the third aperture than the second free end, the protrusions of the third group of protrusions alternate with the protrusions of the fourth group of protrusions.

10. The heat exchanger of claim 9, wherein the alternating protrusions form a first coolant flow channel along the coolant flow path, and wherein the third and fourth groups of protrusions form a second coolant flow channel along the coolant flow path, the second flow channel extending parallel to the first flow channel, the second flow channel being positioned closer to the third aperture than the first flow channel.

11. The heat exchanger of claim 9 or claim 10, further comprising a fifth group of protrusions, the fifth group of protrusions being oriented at an acute angle with respect to the first group of protrusions.

12. The heat exchanger of any of claims 1 to 11, wherein the sheet is fixedly coupled to the first plate and wherein the second free ends are fixedly coupled to the second plate, the protrusions are configured to retain the second plate spaced from the first plate by the passage height.

13. The heat exchanger of any of claims 1 to 11, wherein the at least one protrusion defines the third aperture, the first end of the first protrusion includes a semi-circular shape.

14. The heat exchanger of claim 12, wherein the at least one protrusion is semi dome-shaped extending from the semi-circular first end to an apex of the semi-dome, the second end of the first protrusion positioned at the apex and in abutment with the second plate.

15. The heat exchanger of claim 12 or claim 13, wherein the at least one protrusion functions as a flow guide to direct coolant through the third aperture while reducing the pressure drop of fluid flowing through the third aperture.

16. The heat exchanger of any of claims 1 to 14, wherein the at least one protrusion at least partially defines the fourth aperture.

17. The heat exchanger of claim 16, wherein the at least one protrusion is configured to retain the first plate spaced the passage height from the second plate proximate the fourth aperture.

18. The heat exchanger of claim 17 or claim 18 wherein the at least one protrusion is formed by bending.

19. The heat exchanger of any of claims 16 to 18, further comprising a semi-circular protrusion near the fourth aperture and proximate the at least one protrusion, the semi-circular protrusion configured to guide flow of coolant through the second aperture.

20. The heat exchanger of claim 1, wherein the at least one protrusion extends at an acute angle with respect to the first plate.

21. The heat exchanger of claim 20, wherein the at least one protrusion at least partially defines the fourth aperture, the second free end of the at least one protrusion forms a wave shape having a variable height above the first plate.

22. The heat exchanger of claim 20 or claim 21, further comprising an insert positioned in the fourth aperture between the first plate and the second plate, the at least one protrusion configured to inhibit flow of coolant around the insert.

23. The heat exchanger of any of claims 1 to 22, further comprising a retaining protrusion and an insert, the retaining protrusion at least partially defining the fourth aperture, the retaining protrusion configured to retain the insert between the first plate and the second plate.

24. The heat exchanger of claim 23, wherein the insert is a turbulator and wherein the at least one protrusion inhibits flow around the turbulator.

Images