Heat exchange plate

Abstract

A heat exchange assembly comprising: (1) two or more plates; (2) a plurality of channels formed between the two or more plates; and (3) one or more reservoirs positioned adjacent the plurality of channels and configured to at least temporarily store a temperature control material; wherein the plurality of channels are configured to direct a flow path of the temperature control material between the two or more plates and to provide structural rigidity to the assembly.

Description

Technical Field

[0001] The present invention generally relates to a heat exchange assembly, and more particularly, to a multi-layer heat exchange assembly. Background Art

[0002] Electronic and electrical equipment is commonly required for a variety of tasks across many industries. Such equipment often generates high energy, overheats, or both during continuous operation. For example, one particular industry is the automotive sector, where many vehicles, such as electric vehicles, require rechargeable batteries to power the vehicle. However, these batteries often generate significant heat during operation, which can adversely affect the battery's performance or even prevent it from operating successfully. Consequently, several attempts have been made to provide cooling systems or heat exchange components to maintain the desired battery temperature at or slightly above room temperature.

[0003] One particularly common solution implemented in various vehicles is a heat exchange system in which a coolant flows through a housing in contact with the battery to extract excess heat from the battery. The excess heat is then transferred through the coolant and exhausted along an opposing surface of the heat exchange system that is not in contact with the battery. It is also possible to use refrigerants in conjunction with the vehicle's air conditioning circuits. These solutions allow the system to cool or heat the battery to a desired temperature as needed. However, heat exchange systems typically require structurally rigid metal materials to function properly. These metals typically require excessive manufacturing time, excessive cost, or both. In addition, heat exchange systems typically require complex cores within the housing to direct or divert the coolant when in use. These cores are typically complex to manufacture, heavy, expensive, or a combination of these features. Moreover, most existing heat exchangers are susceptible to impact damage and provide little benefit in terms of battery impact protection.

[0004] Examples of heat exchange systems can be found in U.S. Patent Nos. 5,971,290, 6,124,64, 8,603,660, 9,225,045, 10,035,401, and 10,224,584, and in U.S. Patent Publication Nos. 2011 / 0269008, 2017 / 0025721, and 2019 / 0031044, all of which are incorporated herein by reference for all purposes. There remains a need for a lightweight, cost-effective heat exchange assembly that can also protect the battery from external impact. There is a need for a heat exchange system having one or more metal layers combined with auxiliary components to direct coolant flow. There remains a need for a customizable heat exchange system. There is a need for a heat exchange assembly having a customizable and adjustable channel pattern to direct coolant temperature control material or other temperature control material. There remains a need for a heat exchange system that cools or heats one or more components while also providing structural rigidity and impact protection. There is a need for a heat exchange assembly that also provides structural reinforcement. Summary of the Invention

[0005] The present teachings address one or more current needs by providing a heat exchange assembly comprising: (I) two or more plates; (II) a plurality of channels formed between the two or more plates; and (III) one or more reservoirs connected to or positioned adjacent to the plurality of channels and configured to at least temporarily store a temperature control material, wherein the plurality of channels are configured to direct a flow path of the temperature control material between the two or more plates.

[0006] The present teachings address one or more current needs by providing a heat exchange assembly comprising: a metal or polymer core disposed between two or more plates, wherein a plurality of protrusions, domes, or other geometric shapes form the plurality of channels; an adhesive or other bonding material that forms the plurality of channels, disposed between the two or more plates and provides a structural bond between the layers; a plurality of side walls that abut the end edges of the two or more plates to form a shell surrounding the plurality of channels; a second reservoir, wherein the reservoir is positioned at opposite ends of the plurality of channels such that a temperature control material flows between the reservoirs through the plurality of channels; or a combination thereof.

[0007] The first plate may be metal, while the second plate may be metal or polymer. The reservoir may include an opening adjacent to the plurality of channels, such that the flow path of the temperature control material moves from the reservoir, through the opening, and into the plurality of channels, or vice versa. The flow path of the temperature control material may loop through the plurality of channels in a serpentine pattern. The flow path of the temperature control material may flow through the plurality of channels in a substantially parallel and simultaneous manner. The flow path of the temperature control material may be substantially random. The adhesive may be a foamable or non-foamable material, applied in a desired pattern to one or more of the joining plates and the guiding coolant. After assembly and foaming (if a foamable material is used), the two or more plates may be separated by the thickness of the adhesive. Even if a foamable material is not used, the two or more plates may be separated by the thickness of the adhesive after assembly. The two or more plates may include a coating to protect against galvanic corrosion or other types of corrosion. The two or more plates may include a top plate, a bottom plate, and a middle plate. The plurality of channels may be disposed either between the top plate and the middle plate, or between the middle plate and the bottom plate. The temperature control material can be polyethylene glycol, air, refrigerant, water, ethanol, phase change material or a combination thereof. The core can be formed aluminum or other metal. At least one of the two or more plates can be permeable. One or more reservoirs can be placed at opposite ends of the multiple channels so that the temperature control material flows between the reservoirs through the multiple channels. The multiple channels can be formed by multiple protrusions extending between the two or more plates. The adhesive can maintain structural integrity between -40°C and at least 80°C. The heat exchange assembly can be incorporated into the automotive battery housing. The two or more plates can be separated by one or more spacers to create a desired gap between the two or more plates. The opening of the reservoir can include one or more reinforcing struts or a combination thereof to maintain the opening structure.

[0008] The assembly may include a heating element. The plurality of channels may include heating elements. The assembly may include a heating element and the heating element may include one or more resistance wires. The assembly may include an induction heating component. The assembly may be substantially free of any adhesive material.

[0009] The present teachings address one or more current needs by providing: a lightweight, structural, and impact-resistant heat exchange component; a heat exchange system having one or more metal layers and / or polymer layers; a customizable heat exchange system; a heat exchange component having a customizable and adjustable channel pattern to direct coolant temperature control material; a need for a heat exchange system that cools or heats one or more components while also providing structural rigidity; a heat exchange component that provides structural reinforcement; or a combination thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is an exploded perspective view of the plate assembly;

[0011] Figure 2 It is an exploded perspective view of the coreless board assembly;

[0012] Figure 3A is a top view of the plate assembly showing the circuit flow path of the temperature control material;

[0013] Figure 3B is a top view of the plate assembly showing the parallel flow paths of the temperature control material;

[0014] Figure 3C is a top view of the plate assembly showing the random flow paths of the temperature control material; and

[0015] Figure 4 is a cross-sectional view of the plate assembly showing the flow path of the temperature control material. DETAILED DESCRIPTION

[0016] The explanations and illustrations set forth herein are intended to familiarize others skilled in the art with the present invention, its principles, and its practical applications. The specific embodiments of the present invention set forth are not intended to be exhaustive or limiting. The scope of the present invention should be defined with reference to the appended claims and the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for any purpose. Other combinations are also possible, as will be gathered from the following claims, which are also hereby incorporated by reference into this written specification.

[0017] This application claims the benefit of the priority dates of U.S. Provisional Application Serial No. 62 / 880,942, filed July 31, 2019, and U.S. Provisional Application Serial No. 62 / 975,884, filed February 13, 2020, the contents of both applications are incorporated herein by reference for all purposes.

[0018] The teachings herein are directed to heat exchange assemblies. A heat exchange assembly can be used to reduce or increase the temperature of one or more components by transferring heat from the one or more components via the heat exchange assembly. The heat exchange assembly can be adjacent to one or more surfaces of the component being cooled or heated. The heat exchange assembly can support the component being cooled or heated. For example, the heat exchange assembly can be integrated into a battery housing that supports or surrounds a vehicle battery. The heat exchange assembly can include one or more layers, one or more coolants, one or more housings, or a combination thereof. The heat exchange assembly can include one or more circulating temperature control materials. The temperature control materials can be circulated through the heat exchange assembly by one or more pumps, one or more motors, one or more impellers, one or more propellers, or a combination thereof. The heat exchange assembly can be corrosion-resistant. The heat exchange assembly can be moisture-resistant. The heat exchange assembly can include one or more baffle materials. The one or more baffle materials can reduce noise from the heat exchange assembly, absorb noise from the heat exchange assembly, or both. The heat exchange assembly can be isotropic, such that the heat exchange assembly is substantially uniform in different directions. Conversely, the heat exchange assembly can be anisotropic, such that the heat exchange assembly has different mechanical and / or material properties when measured in opposite directions. For example, the heat exchange assembly may be structurally rigid along a longitudinal axis and flexible along an axis perpendicular to the longitudinal axis.

[0019] The heat exchange assembly may include two or more plates. The plates may serve to form the outer shell of the heat exchange assembly. The plates may serve to surround the interior of the heat exchange assembly to form an outer shell. The plates may support the component being cooled or heated. The plates may serve as the initial point of contact between the component and the heat exchange assembly, transferring heat to the component or from the component to the heat exchange assembly. For example, the top plate of the heat exchange assembly may support and abut the bottom of the battery, allowing heat to initially transfer from the battery to the top plate, and vice versa. The plates may preferably be structurally rigid. The plates may be flexible. The plates may be moisture-resistant, corrosion-resistant, antimicrobial, antifungal, or a combination thereof. For example, the plates may include one or more coatings to protect against galvanic or other types of corrosion. The plates may be permeable. The plates may include one or more holes, gaps, spaces, or a combination thereof to form a permeable layer. The plates may be substantially moisture-proof or airtight to prevent leakage of coolant temperature control material flowing through the interior of the heat exchange assembly.

[0020] The plates can be of any desired shape and material. The plates can have any desired thickness. The plates can have a thickness of less than 1 mm, about 1 mm or more, about 2 mm or more, or about 3 mm or more. The plates can have a thickness of less than about 6 mm, less than about 5 mm, or less than about 4 mm. The plates can be metal. For example, the plates can be aluminum, iron, steel, copper, bronze, or a combination thereof. Alternatively, the plates can be polymeric. For example, the plates can be a polyamide material reinforced with fiberglass. The plates can be the same material or can be of different materials. For example, the top and bottom plates can be metal, while one or more intermediate plates can be polyamide. The plates can include one or more bends, one or more arcuate portions, one or more straight segments, one or more curves, one or more protrusions, one or more cutouts, one or more recesses, one or more fillets, one or more holes, or a combination thereof. The plates can be substantially planar. For example, the plates can be substantially sheet-like.

[0021] The plates can be positioned in any position relative to each other. The plates can be spaced apart to form a desired gap between the plates. The gap can be selected based on the interior of the heat exchange assembly. For example, the gap between the plates can form a cavity filled with one or more adhesives, one or more cores, or both. The plates can be positioned substantially coplanar with each other. For example, the plates can be connected along the peripheral edges to form the overall dimensions of the heat exchange assembly. The plates can be arranged substantially parallel to each other, perpendicular to each other, or both parallel and perpendicular to each other. The plate can be a single plate. The plate can be a plurality of plates. The heat exchange assembly can include approximately one or more plates, approximately two or more plates, or approximately three or more plates. The heat exchange assembly can include approximately six or fewer plates, approximately five or fewer plates, or approximately four or fewer plates. The plates can form one or more internal cavities of the heat exchange assembly. The one or more internal cavities can include one or more interior portions of the heat exchange assembly.

[0022] The plates may be separated by one or more spacers. The spacers may serve to maintain a desired gap between the plates. The spacers may abut the surface of one or more plates. The spacers may be compressible. The spacers may be structurally rigid. The spacers may be of any size and shape. The spacers may have any desired length to form the desired gap. For example, the spacers may have a thickness of less than 1 mm, about 1 mm or more, about 2 mm or more, or about 3 mm or more. The spacers may have a thickness of less than about 6 mm, about 5 mm or less, or about 4 mm or less. The spacers may be adhered to the plates. The spacers may be secured to the plates using one or more fasteners. The spacers may be removable. The heat exchange assembly may include multiple spacers. The heat exchange assembly may be free of spacers. For example, the desired gap between the plates may be maintained without spacers.

[0023] The plates may be connected to one or more sidewalls. The sidewalls may serve to protect the interior of the heat exchange assembly. The sidewalls may abut the outer edges of the plates. The sidewalls may be positioned within the gaps between the plates. The sidewalls may define the desired height of the heat exchange plates. The sidewalls, combined with the plates, may form the integral housing of the heat exchange assembly. The sidewalls may abut the components being cooled or heated. The sidewalls may serve as the initial point of contact between the heat exchange assembly and the components being cooled or heated. The sidewalls may be secured to the plates. The connection may be formed using one or more mechanical fasteners, one or more adhesives, one or more sealants, or a combination of these. For example, the connection may be formed using one or more bolts, welding, or both. The sidewalls may be integrally formed with one or more plates. The sidewalls may have any desired size or shape. The shape of the sidewalls may be substantially similar to that of the plates, or may be different. The length of the sidewalls may be substantially equal to that of the plates. The sidewalls may form a sealed enclosure with the plates. For example, the sidewalls and plates may form an airtight enclosure, a waterproof enclosure, a leakproof enclosure, or a combination thereof. The sidewalls may abut the sides of the core.

[0024] The core may function as an internal component forming the heat exchange assembly. The core may function to divert, direct, or both divert and direct the flow path of the temperature control material of the heat exchange assembly. The core may be positioned between the plates, between the sidewalls, or between the plates and the sidewalls. The core may be positioned within the internal cavity of the heat exchange assembly. The core may provide structural reinforcement for the heat exchange assembly. The core may be structurally rigid or flexible. The core may have a shape similar to the plates, the sidewalls, or both. For example, the core and the plates, the sidewalls, or both may be of equal extent. When the plates abut opposing surfaces of the core, the core may be positioned between the plates to form a desired gap between the plates. The core may be a single, integrally formed structure. Alternatively, the core may include one or more interconnected parts. The core may form a path for the coolant temperature control material. For example, the core may include one or more protrusions, one or more ribs, one or more channels, one or more cavities, one or more walls, one or more protrusions, one or more ribs, one or more grooves, or a combination thereof to direct, deflect, or both direct and deflect the temperature control material. The core may include one or more bends, one or more arcuate portions, one or more linear segments, one or more cross members, or a combination thereof. The core may be integrally (i.e., monolithically) formed from one or more plates. For example, the plates may include a plurality of protrusions or a plurality of ribs that, when joined to opposing plates, form a plurality of channels between the plates, which may represent the core. Alternatively, the core may be a separate piece that is connected to one or more plates during assembly. The core may be joined to the plates by one or more fasteners, one or more adhesives, one or more sealants, or more than one of these.

[0025] The core can be any desired material. The core can be metallic, polymeric, or both. The core can be a corrugated material. The core can be extruded, pultruded, molded, stamped, embossed, cast, or a combination thereof. The core can include one or more coatings. The one or more coatings can protect the core from corrosion, degradation, or both. The coatings can also aid in adhesion, sealing, or both. The core can be permeable.

[0026] The core may include a plurality of ribs. The ribs may contribute to the core's overall shape. The ribs may provide structural integrity to the heat exchange assembly. The ribs may serve to connect the core to the plates, sidewalls, or both. The ribs may serve to divert and direct the flow path of the coolant temperature control material. The ribs may be interconnected or spaced apart. The ribs may extend along the longitudinal axis of the core. The ribs may extend substantially parallel to the longitudinal axis of the core. The ribs may extend at any angle relative to the longitudinal axis of the core. For example, the ribs may extend substantially transversely to the length of the core. The ribs may create one or more spines that extend along the length, width, or both of the core. For example, the core may include a plurality of substantially uniform ribs that extend substantially parallel to one another along the length of the core. The ribs may have a desired height. The ribs may have a height of approximately 1 mm or greater, approximately 2 mm or greater, or approximately 3 mm or greater. The ribs may have a height of approximately 6 mm or less, approximately 5 mm or less, or approximately 4 mm or less. The length of the ribs may be substantially equal to or less than the length of the core. The length of the ribs may be substantially equal to or less than the width of the core. The ribs may be integrally formed with the core. The ribs may be inserted into the core. For example, one or more rods may be inserted into the core.

[0027] Adhesive material or other connecting means can be used in place of or in conjunction with the core. The adhesive material can serve to secure the plates to each other. The plates can be welded or brazed together. The adhesive material or other connecting means can serve to form an inner portion between the plates that receives the coolant temperature control material. The adhesive material can create a desired gap between the plates. The adhesive material can form a path for the coolant temperature control material. The adhesive material can be disposed on one or more surfaces of one or more plates. The adhesive material can create one or more gaps, one or more cavities, or both between the plates. The adhesive material can join the plates, sidewalls, or both together to form the housing of the heat exchange assembly. For example, the adhesive material can be disposed on the mating surface of a top plate that is adjacent to the mating surface of a bottom plate. The adhesive material can reinforce the heat exchange assembly. The adhesive material can block noise from the heat exchange assembly.

[0028] The adhesive material can be provided on one or more plates to form any desired shape. The adhesive material can be provided using one or more extrusion methods, such as a robotic applicator. The adhesive material can be provided in a substantially uniform pattern. The adhesive material can be arranged in a substantially non-uniform pattern. The adhesive material can form one or more pathways for the coolant temperature control material. The adhesive material can be provided along any portion of the plate. The adhesive material can be provided along a portion or all of one or more plates. For example, the adhesive material can be provided along substantially all of one or more plates and the adhesive material can be permeable so that the coolant temperature control material can flow through the adhesive material. Thus, the adhesive material can form a pattern that guides the temperature control material, deflects the temperature control material, or both guides and deflects, and is used in place of a core. Alternatively, the adhesive material can form part of the flow path of the temperature control material in conjunction with the core.

[0029] The adhesive material can be any adhesive material compatible with the coolant / refrigerant composition. The adhesive material can be expandable upon activation. The adhesive material can be heat-activated, activated by an activator, or both. The adhesive material can be foamable. The adhesive material can be heat-activated. The adhesive material can be curable. The adhesive material can be cured at elevated temperatures during the manufacturing process. Alternatively, the adhesive material can cure at room temperature and does not require elevated temperatures for curing. The adhesive can have an expected working time of up to one day. The adhesive can have a desired curing time. The curing time can be about 30 seconds or more, about 1 minute or more, or about 5 minutes or more. The curing time can be about 10 minutes or less, about 8 minutes or less, or about 6 minutes or less. The adhesive material can be dry or tacky to the touch prior to activation. The adhesive material can be room temperature stable. The adhesive material can include an adhesive polymer material (e.g., epoxy resin, etc.). The adhesive material can include one or more of the following: epoxy resin; toughening agent; phenoxy resin; impact modifier; blowing agent; curing agent; filler; or a combination thereof. If the adhesive material is expandable or foamable, the adhesive material can expand to a volume that is larger (e.g., at least 5% larger, at least 20% larger, or even possibly at least 50% larger) than its volume in the unexpanded state. The volume expansion can be about 400% or less, about 300% or less, or about 200% or less relative to the original unexpanded volume. The volume expansion can be about 50% or more, about 100% or more, or about 150% or more relative to the original unexpanded volume. Alternatively, for the adhesive material in foamed and / or unfoamed form, the volume of the adhesive material can be smaller after activation due to curing (e.g., cross-linking). Multiple adhesive materials can be provided on one or more surfaces of the plate, sidewalls, core, or more than one of these. Examples of adhesive materials can be found in US Pat. Nos. 6,846,559, 6,923,499, 7,125,461, 7,199,165, 7,521,093, 7,892,396, 8,236,128, 8,334,055, 8,475,694, and 8,702,889, all of which are incorporated herein by reference for any purpose.

[0030] The assembly can be substantially free of any adhesive material. The adhesive material can be formed into a plurality of protrusions. The protrusions can function to divert the flow path of the coolant temperature control material. The protrusions can extend between opposing plates. The protrusions can be of any size and shape. The protrusions can be structurally rigid. The protrusions can be tapered. The protrusions can have any cross-sectional shape. The protrusions can extend from the plates, side panels, or both at any desired angle.

[0031] The protrusions, the adhesive material, or both may form a plurality of channels. The channels may function to receive and direct the coolant temperature control material of the heat exchange assembly. The channels may function to form flow paths for the coolant temperature control material. The channels may be formed between the protrusions of the channel. The channels may extend substantially parallel to one another. The channels may extend substantially perpendicular to one another. The channels may extend at any angle relative to one another. The channels may interconnect. The channels may intersect. The channels may interconnect to form a single overall temperature control material path. Alternatively, the channels may form multiple temperature control material paths, such that the temperature control material may move through the multiple temperature control material paths substantially simultaneously.

[0032] The channel can be of any size and shape. The channel can be U-shaped, V-shaped, C-shaped, D-shaped, circular, square, rectangular, triangular, or a combination thereof. The channel can have any desired cross-sectional dimensions. For example, the width of the cross-section of the channel can be substantially equal to the gap between the plates. The channel can include one or more bends, one or more curved portions, one or more straight segments, or a combination thereof. The channel can include one or more openings, one or more holes, or both. For example, the channel can include one or more openings positioned near opposite ends of the channel. The channel can be substantially closed. The channel can be partially open.

[0033] The channel can be fluidically connected to one or more reservoirs. The reservoir can serve to at least temporarily store the coolant temperature control material. The reservoir can be fluidically connected to the channel formed by the adhesive, the core, or both, so that the coolant temperature control material can flow from the reservoir through the channel, and vice versa. The reservoir can be placed near the opposite end of the channel. The reservoir can be fixed to the plate, sidewall, core, adhesive material, sealant, or a combination thereof. The reservoir can be of any size and shape. The reservoir can be leakproof (e.g., airtight). The reservoir can have sufficient capacity to maintain the desired temperature control material level throughout the heat exchange assembly.

[0034] Multiple reservoirs can be interconnected. The reservoirs can be connected to each other directly or indirectly. For example, the reservoirs can be indirectly connected to each other via a channel, allowing coolant temperature control material to flow from a first reservoir through the channel and into a second reservoir. In this manner, the coolant temperature control material can then be recirculated through a pump, impeller, propeller, turbine, or a combination thereof to form a closed-loop system. Alternatively, the reservoirs can contribute to an open-loop system without recirculating the coolant temperature control material.

[0035] The reservoir may include one or more apertures. The apertures may serve as an inlet for the coolant temperature control material, an outlet for the coolant temperature control material, or both. The apertures may be positioned anywhere along the reservoir. The apertures may be of any size and shape. The apertures may allow the temperature control material to enter, exit, or both from a cavity within the reservoir. The apertures may include a covering, lid, plug, or a combination thereof to prevent undesirable escape of the coolant temperature control material during use. The covering, lid, plug, or a combination thereof may be removable to allow the reservoir to be filled. The apertures may connect one or more tubes to the heat exchange assembly to form an open-loop system, a closed-loop system, or both.

[0036] The reservoir may include an opening. The opening may serve to establish temperature control material communication between the reservoir and the interior of the heat exchange assembly. For example, coolant temperature control material may flow from the reservoir, through the opening, and into one or more channels of the heat exchange assembly. The opening may be any desired size and shape. The opening may be tapered or may remain a uniform size. The opening may be connected to the heat exchange assembly. For example, the opening may be received by a recess in the heat exchange assembly. Alternatively, the reservoir may be secured to the heat exchange assembly by one or more fasteners, one or more adhesives, or both, such that the opening is adjacent to the interior of the heat exchange assembly. The adjacent portion between the interior of the heat exchange assembly and the opening may be free of gaps and clearances to prevent leakage or undesired discharge of the coolant temperature control material.

[0037] The opening may include one or more struts. The struts may serve to structurally reinforce the opening. The struts may be structurally rigid. The struts may be positioned anywhere along the opening. The struts may extend between opposing walls of the opening. The struts may be of any size and shape. The struts may be spaced a desired length apart. The struts may extend into the reservoir. The struts may be aligned with one or more channels of the heat exchange plate. The struts may deflect the coolant temperature control material to reduce the flow rate of the coolant temperature control material entering the interior of the heat exchange assembly. The struts may be removable. The struts may be adjustable. The struts may be fixed to the heat exchange assembly.

[0038] A heat exchange temperature control material can flow through the heat exchange assembly. The temperature control material can maintain the temperature of one or more cooled components, the temperature of the heat exchange assembly, or both. The temperature control material can be any desired temperature control material. The temperature control material can be a liquid, a gas, or both. The temperature control material can be air. The temperature control material can be water, ethanol, or both. The temperature control material can be a glycol mixture. For example, the temperature control material can be polyethylene glycol. The temperature control material can be a low-silicate temperature control material. The temperature control material can be a refrigerant. For example, the temperature control material can be a fluorocarbon, particularly a chlorofluorocarbon, ammonia, sulfur dioxide, and a non-halogenated hydrocarbon such as propane. The temperature control material can be a phase change material, such that it does not flow but instead melts or solidifies within a desired temperature range (most desirably ~25-30°C for batteries). While melting, the phase change material can absorb heat from the battery. Then, at a lower temperature, the phase change material can resolidify, thereby helping to insulate the battery from the cold. The temperature can be controlled by one or more heating elements placed in one or more channels or reservoirs, or otherwise associated with the assembly. The heating element may comprise one or more resistance wires. The heating element may be heated by an induction heating system.

[0039] The temperature control material can be propelled through the heat exchange assembly by one or more impellers, one or more propellers, one or more pumps, or a combination thereof. The temperature control material can have any desired flow rate, pressure, or both. The temperature control material can be in a closed loop system, an open loop system, or both. The temperature control material can be recirculated. The temperature control material can be filtered during the recirculation process.

[0040] Now turning to the accompanying drawings, Figure 1 A perspective view of a heat exchange assembly 10 is shown. The heat exchange assembly 10 includes a plurality of plates 12 surrounding a core 16. A top plate 16A and a bottom plate 16B are positioned on opposing surfaces of the core 16. In addition, opposing side walls 14 abut the sides of the core 16 such that the side walls 16 and plates 12 form an outer shell of the core 16. The core 16 includes a plurality of protrusions 24, which may be ribs extending generally along or parallel to the longitudinal axis of the core 16. The plurality of protrusions 24 form a plurality of channels 18 that may receive and direct a flow path of a temperature control material (see Figures 3 and 4). Figure 4 The heat exchange assembly 10 also includes opposing reservoirs 20, each having an aperture 26 for receiving a temperature control material, discharging the temperature control material, or both. The reservoirs 20 each include an opening 22 having a plurality of reinforcing struts 32 adjacent opposing ends of the core 16 to allow the temperature control material to flow between the reservoirs 20 through the core 16.

[0041] Figure 2A perspective view of a heat exchange assembly 10 is shown. The heat exchange assembly 10 includes a plurality of plates 12. The top plate 16A, the bottom plate 16B, or both may include an adhesive material 28 disposed on one or more surfaces. The adhesive material 28 may be configured to form a specific shape, path, pattern, or combination thereof to direct the flow path of the temperature control material. For example, the adhesive material 28 may form a plurality of channels that direct the flow path of the temperature control material (see Figures 3 and 4). Figure 4 ). The adhesive material 28 can have a desired thickness such that when the top plate 12A and the bottom plate 12B are adjacent to the adhesive material 28, a desired gap (G) is created between the plates 12 that is substantially related to the thickness (i.e., height) of the adhesive material 28. The gap (G) can be maintained by one or more spacers 36 disposed between the plates 12. The adhesive material 28 can be applied to the plates 12 having a desired height, can be cured to expand to a desired height, or both. In addition, the opposing side walls 14 are adjacent to the edges of the adjacent plates 12 within the gap (G) such that the side walls 16 and the plates 12 form a shell around the adhesive material 28. The exchange assembly 10 also includes opposing reservoirs 20, each having a hole 26 to receive the temperature control material, discharge the temperature control material, or both. The reservoirs 20 each include an opening 22 having a plurality of reinforcing struts 32, the reinforcing struts 32 being adjacent to opposing ends of the plates 12 so that the temperature control material can flow between the reservoirs 20 through the pattern created by the adhesive material 28.

[0042] Figures 3A-3C A top view of a heat exchange assembly 10 having a varying temperature control material flow path is shown. As shown, the heat exchange assembly 10 includes opposing reservoirs 20 each having an aperture 26. The reservoirs 20 are positioned on opposite sides of the heat exchange assembly 10 such that temperature control material 30 can flow between the reservoirs 20 through the heat exchange assembly 10. Figure 1 and Figure 2 As shown, the heat exchange assembly 10 may include a core, a binder material, or both, that creates one or more channels, flow paths, protrusions 20, or a combination thereof, to divert and define the flow path of the temperature control material. Figure 3A As shown, the temperature control material 30 can flow in a substantially loop path through the channels of the heat exchange assembly 10. Figure 3B As shown, the temperature control material 30 can have multiple temperature control material paths that travel substantially parallel to each other through multiple channels of the heat exchange assembly 10. Alternatively or in addition, the temperature control material 30 can have a substantially random flow path around one or more adhesive protrusions 34 of the heat exchange assembly 10, as shown. Figure 3C shown.

[0043] Figure 4A cross-sectional view of a heat exchange assembly 10 is shown. The heat exchange assembly 10 includes a plurality of plates 12 separated by one or more adhesive materials 28. The top plate 12A and the middle plate 12C are separated by the adhesive material 28, and similarly, the middle plate 12C and the bottom plate 12B are also separated by the adhesive material 28. The adhesive material 28 can form a plurality of channels 18 so that a temperature control material 30 can flow through the channels. In addition, one or more of the plates 12 can be permeable (e.g., the middle plate 12C) so that the temperature control material 30 can also flow through the plates 12. The heat exchange assembly 10 can further include opposing reservoirs 20. As shown, the temperature control material 30 can flow into the temperature control material inlet (F I ), passes through the heat exchange assembly 10, and flows out of the temperature control material outlet F O It should be noted that the temperature control material 30 can be recirculated to continuously flow in the desired path. The temperature control material can be recirculated by one or more pumps, one or more impellers, one or more propellers, or a combination thereof (not shown).

[0044] Unless otherwise stated, the size and geometry of the various structures described herein are not intended to limit the present invention, and other sizes or geometries are possible. A plurality of structural components can be provided by a single integrated structure. Alternatively, a single integrated structure may be divided into independent multiple components. In addition, although feature of the present invention may only be described in the context of an illustrated embodiment, yet for any given application, this feature can be combined with one or more other features of other embodiments. From the above, it can also be understood that the manufacture of the unique structure herein and its operation also constitute method according to the present invention.

[0045] Unless otherwise indicated, the term "about" or "approximately" in combination with a numerical value encompasses the stated amount as well as the approximate value of the stated amount. For example, the term "about 100" encompasses 100 + / - 15.

[0046] While preferred embodiments of the present invention have been disclosed, those skilled in the art will appreciate that certain modifications may be made within the scope of the present invention. Therefore, the following claims should be studied to determine the true scope and content of the present invention.

[0047] The explanations and illustrations presented herein are intended to familiarize other persons skilled in the art with the present invention, its principles, and its practical applications. Those skilled in the art may adjust and apply the present invention in a variety of forms that best suit the requirements of a particular application. Thus, the specific embodiments of the present invention set forth are not intended to be exhaustive or limiting. Therefore, the scope of the present invention should not be determined with reference to the above description, but rather with reference to the full scope of equivalents granted by the appended claims and these claims. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for any purpose. Other combinations are also possible, as will be gathered from the following claims, which are also incorporated by reference into this written specification.

Claims

1. A heat exchange assembly comprising: (I) two or more plates; (II) a plurality of channels formed between the two or more plates; the plurality of channels being formed from a foamable adhesive material disposed between the two or more plates; and (III) a reservoir positioned adjacent the plurality of channels and configured to at least temporarily store a temperature control material selected from the group consisting of polyethylene glycol, air, a refrigerant, water, ethanol, a phase change material, or a combination thereof; wherein the plurality of channels are configured to direct a flow path of the temperature control material between the two or more plates; and wherein the plurality of channels provide structural rigidity to the heat exchange assembly.

2. The heat exchange assembly of claim 1, wherein the first plate is metallic and the second plate is metallic or polymeric.

3. The heat exchange assembly of any one of the preceding claims, further comprising a plurality of side walls adjoining end edges of the two or more plates to form an enclosure surrounding the plurality of channels.

4. The heat exchange assembly of claim 1 or 2, wherein the reservoir includes an opening adjacent the plurality of channels such that a flow path for the temperature control material moves from the reservoir, through the opening, and into the plurality of channels, or vice versa.

5. The heat exchange assembly of claim 1 or 2, wherein the flow path of the temperature control material loops through the plurality of channels in a serpentine pattern.

6. The heat exchange assembly of claim 1 or 2, wherein the flow path of the temperature control material flows through a plurality of channels in a parallel and simultaneous manner.

7. The heat exchange assembly of claim 1 or 2, wherein the flow path of the temperature control material is random.

8. The heat exchange assembly of claim 1, wherein the two or more plates are separated by a thickness of the foamable adhesive material after expansion of the foamable adhesive material.

9. The heat exchange assembly of claim 1 or 2, wherein the two or more plates include a coating to protect against galvanic or other types of corrosion.

10. The heat exchange assembly of claim 1 or 2, wherein the two or more plates include a top plate, a bottom plate, and a middle plate, and the plurality of channels are disposed between the top plate and the middle plate, and between the middle plate and the bottom plate.

11. The heat exchange assembly of claim 1 or 2, wherein at least one of the two or more plates is permeable.

12. The heat exchange assembly of claim 1 or 2, further comprising a second reservoir, wherein the reservoirs are positioned at opposite ends of the plurality of channels such that the temperature control material flows between the reservoirs through the plurality of channels.

13. The heat exchange assembly of claim 1, wherein the foamable adhesive material maintains structural integrity between -40°C and 80°C.

14. The heat exchange assembly of claim 1 or 2, wherein the plurality of channels have a height greater than 0.3 mm.

15. The heat exchange assembly of claim 4, wherein the opening includes one or more reinforcing struts that maintain the structure of the opening.

16. The heat exchange assembly of claim 1 or 2, wherein the assembly comprises a heating element.

17. The heat exchange assembly of claim 1 or 2, wherein the plurality of channels comprise heating elements.

18. The heat exchange assembly of claim 1 or 2, wherein the assembly comprises a heating element and the heating element comprises one or more resistance wires.

19. The heat exchange assembly of claim 1 or 2, wherein the assembly includes an induction heating component.

20. An automotive battery housing comprising one or more heat exchange assemblies according to any one of the preceding claims.

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