Vehicle heat exchanger

Abstract

The present disclosure provides a vehicle heat exchanger. A battery cooler for a vehicle includes a housing having a first inlet, a second inlet opposite the first inlet, a first outlet having an annular structure surrounding the second inlet, and a second outlet having an annular structure surrounding the first inlet. A lattice is disposed within the housing, the lattice defining a first plurality of channels and a second plurality of channels. The lattice defines a first inlet conduit in fluid communication with the first inlet and the first channel, and a second inlet conduit in fluid communication with the second inlet and the second channel. A first flow path is defined from the first inlet, through the first inlet conduit, through the first plurality of channels, and to the first outlet, and a second flow path is defined from the second inlet, through the second inlet conduit, through the second plurality of channels, and to the second outlet.

Description

Technical Field

[0001] The present disclosure relates generally to a heat exchanger, and more particularly to a heat exchanger for a vehicle, such as a battery cooler for a vehicle. Background Art

[0002] A motor vehicle may include an energy storage system, such as a battery system. The battery system may generate excess heat when charging or discharging, which may cause the battery system temperature to rise to an elevated operating temperature. A compact and efficient cooling system is desired to cool the battery system and maintain a desired operating temperature. Summary of the invention

[0003] According to a first aspect of the present disclosure, a heat exchanger for a vehicle is provided. The heat exchanger includes a shell and a coolant outlet, the coolant outlet being defined on a first end of the shell. The coolant outlet has a first annular structure having a first central opening. The refrigerant outlet is defined on a second end of the shell. The refrigerant outlet has a second annular structure having a second central opening. A coolant inlet is defined on the second end of the shell. The coolant inlet is arranged through the second central opening of the refrigerant outlet. The refrigerant inlet is defined on the first end of the shell. The refrigerant inlet is arranged through the first central opening of the coolant outlet. A lattice structure is provided in the shell, the lattice structure defining a plurality of coolant channels and a plurality of refrigerant channels. The lattice structure defines a coolant conduit in fluid communication with the plurality of coolant channels and a refrigerant conduit in fluid communication with the plurality of refrigerant channels. The coolant outlet is in fluid communication with the plurality of coolant channels of the lattice structure, and the refrigerant outlet is in fluid communication with the plurality of refrigerant channels of the lattice structure.

[0004] Embodiments of the first aspect of the present disclosure may include any one or a combination of the following features:

[0005] - the first annular structure of the coolant outlet is a first circular ring structure, and wherein the second annular structure of the refrigerant outlet is a second circular ring structure;

[0006] - the lattice structure is a helical tetrahedron structure;

[0007] - the housing has a central portion, a first tapered portion extending from the central portion toward the first annular structure, and a second tapered portion extending from the central portion toward the second annular structure;

[0008] - The housing and the lattice structure consist of the same material.

[0009] - a refrigerant flows along a refrigerant flow path defined from the refrigerant inlet, through the refrigerant conduit, through the plurality of refrigerant channels and to the refrigerant outlet, and wherein a coolant flows along a coolant flow path defined from the coolant inlet, through the coolant conduit, through the plurality of coolant channels and to the coolant outlet;

[0010] - the refrigerant inlet and the refrigerant outlet are coupled to a refrigeration circuit, and wherein the coolant inlet and the coolant outlet are coupled to a vehicle battery system, and further, wherein the refrigerant flows through the refrigeration circuit and the coolant flows through the vehicle battery system;

[0011] - the heat exchanger is configured as an evaporator of the refrigeration circuit;

[0012] the heat exchanger comprises: a coolant outlet pipe coupled to the first annular structure; and a refrigerant outlet pipe coupled to the second annular structure, wherein the refrigerant pipe is arranged along the bottom surface of the shell and close to the coolant outlet pipe; and

[0013] The heat exchanger comprises a mounting bracket coupled to the housing, wherein the coolant outlet pipe and the refrigerant outlet pipe are routed through the mounting bracket.

[0014] According to a second aspect of the present disclosure, a heat exchanger for a vehicle battery system is provided. The heat exchanger includes a housing, a first inlet on a first end of the housing, and a first outlet on a second end of the housing. The first outlet has a first annular structure defining a first central opening. The housing also includes a second inlet on the second end of the housing, and a second outlet on the first end of the housing. The second inlet is arranged through the first central opening of the first outlet. The second outlet has a second annular structure defining a second central opening, and the first inlet is arranged through the second central opening of the second outlet. A spiral 24-hedron structure is disposed in the housing, the spiral 24-hedron structure defining a first plurality of channels and a second plurality of channels. The spiral 24-hedron structure defines a first inlet cone in fluid communication with the first inlet and a second inlet cone in fluid communication with the second inlet. A first flow path is defined as from the first inlet of the housing, through the first inlet cone, through the first plurality of channels, and to the first outlet. A second flow path is defined as from the second inlet of the housing, through the second inlet cone, through the second plurality of channels, and to the second outlet.

[0015] Embodiments of the second aspect of the present disclosure may include any one or a combination of the following features:

[0016] - the first inlet and the first outlet are coupled to the vehicle battery system, and wherein the second inlet and the second outlet are coupled to a refrigeration circuit;

[0017] - the heat exchanger is configured as an evaporator of the refrigeration circuit;

[0018] The heat exchanger further comprises: a first outlet pipe coupled to the first annular structure; and a second outlet pipe coupled to the second annular structure, wherein the second pipe is arranged along the bottom surface of the housing and close to the first outlet pipe;

[0019] The heat exchanger further comprises a support bracket coupled to the first outlet pipe and the second outlet pipe.

[0020] According to a third aspect of the present disclosure, a battery cooler for a vehicle battery system is provided. The battery cooler includes a housing having a first inlet, a second inlet opposite to the first inlet, a first outlet having a first annular structure surrounding the second inlet, and a second outlet having a second annular structure surrounding the first inlet. A minimum surface structure is disposed within the housing, the minimum surface structure defining a first plurality of channels and a second plurality of channels. The minimum surface structure defines a first inlet conduit in fluid communication with the first inlet and the first plurality of channels, and a second inlet conduit in fluid communication with the second inlet and the second plurality of channels. A first flow path is defined as from the first inlet, through the first inlet conduit, through the first plurality of channels and to the first outlet, and a second flow path is defined as from the second inlet, through the second inlet conduit, through the second plurality of channels and to the second outlet.

[0021] Embodiments of the third aspect of the present disclosure may include any one or a combination of the following features:

[0022] – the minimum surface structure is a helical tetrahedron structure;

[0023] - the annular structure outlet is a first circular ring structure, and the second annular structure is a second circular ring structure;

[0024] - the first inlet and the first outlet are coupled to the vehicle battery system, and the second inlet and the second outlet are coupled to a vehicle battery refrigeration system, and wherein coolant flows along the first flow path through the vehicle battery system and returns to the first inlet, and further, wherein refrigerant flows along the second flow path through the minimum surface structure and returns to the second inlet; and

[0025] –The battery cooler also includes: a first outlet pipe, which is connected to the first annular structure; a second outlet pipe, which is connected to the second annular structure, wherein the second pipe is arranged along the bottom surface of the shell and close to the first outlet pipe; and a support bracket, which is connected to the first outlet pipe and the second outlet pipe.

[0026] These and other features, advantages and objectives of the present disclosure will be further understood and appreciated by those skilled in the art by referring to the following description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the attached picture:

[0028] Figure 1 is a front perspective view of an electric motor vehicle equipped with a heat exchanger configured to cool a battery system according to one embodiment;

[0029] Figure 2 is a front perspective view of a heat exchanger;

[0030] Figure 3 is a rear perspective view of the heat exchanger;

[0031] Figure 4 is a side elevation view of a heat exchanger;

[0032] Figure 5 It passes through Figure 2 A side cross-sectional view of the heat exchanger taken along line VV in FIG.

[0033] Figure 6 It passes through Figure 2 A side cross-sectional view of the heat exchanger taken along line VI-VI in FIG.

[0034] Fig. 7A is a block diagram of a vehicle cooling system including a heat exchanger for cooling a heat source according to one example; and

[0035] Figure 7B is a block diagram of a vehicle cooling system including a heat exchanger configured to cool a battery system. DETAILED DESCRIPTION

[0036] Reference will now be made in detail to the present preferred embodiments of the present disclosure, examples of which are shown in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. In the drawings, the depicted structural elements are not drawn to scale, and certain parts are enlarged relative to other parts for the purpose of emphasis and understanding.

[0037] As required, detailed embodiments of the present disclosure are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the present disclosure, which may be implemented in various alternative forms. The drawings are not necessarily designed in detail; some schematic diagrams may be enlarged or minimized to show functional overviews. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to adopt the present disclosure in different ways.

[0038] For the purpose of this description, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives shall be used in conjunction with Figure 4 The present invention relates to the concept of orientation in the present invention. However, it should be understood that the concept can present various alternative orientations unless expressly specified to the contrary. It should also be understood that the specific devices and processes shown in the drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, unless the claims expressly state otherwise, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting.

[0039] The embodiments shown herein reside primarily in a combination of method steps and apparatus components associated with a heat exchanger having a minimal surface structure defining a first volume and a second volume. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, and only those specific details relevant to understanding the embodiments of the present disclosure are shown so as not to obscure the present disclosure by details that are readily apparent to one of ordinary skill in the art having the benefit of the description herein. Additionally, like reference numerals in the specification and drawings represent like elements.

[0040] As used herein, the term "and / or" when used with a list of two or more items means that any one of the listed items may be employed alone, or any combination of two or more of the listed items may be employed. For example, if a composition is described as containing components A, B, and / or C, the composition may contain: A alone; B alone; C alone; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0041] In this document, relative terms such as first and second, top and bottom, etc. are used only to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover non-exclusive inclusions, such that a process, method, article, or apparatus comprising a list of elements includes not only those elements, but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises ..." does not, in the absence of more constraints, preclude the presence of additional identical elements in the process, method, article, or apparatus comprising the element.

[0042] As used herein, the term "about" means that the amount, size, formula, parameter and other quantities and characteristics are not exact, nor do they need to be exact, but can be approximate and / or larger or smaller as needed to reflect tolerances, conversion factors, rounding, measurement errors, etc., and other factors known to those skilled in the art. When the term "about" is used to describe the endpoints of a value or range, the disclosure should be understood to include the specific value or endpoint mentioned. Regardless of whether the endpoints of a numerical value or range in this specification are described as "about", the endpoints of the numerical value or range are intended to include two embodiments: one modified by "about" and one not modified by "about". It should also be understood that the endpoints of each range in the range are significant in relation to the other endpoint and independently of the other endpoint.

[0043] As used herein, the terms "substantially," "substantially," and variations thereof are intended to indicate that the feature being described is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to indicate a planar or approximately planar surface. Additionally, "substantially" is intended to mean that two values ​​are equal or approximately equal. In some embodiments, "substantially" may indicate that values ​​are within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0044] Unless expressly indicated to the contrary, as used herein, the terms "the," "a," or "an" mean "at least one" and should not be limited to "only one." Thus, for example, reference to "a component" includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0045] refer to Figure 1, reference numeral 20 generally represents a wheeled car or motor vehicle. According to one example, the motor vehicle 20 may be an electric vehicle having a battery system 152 that supplies power to one or more motors. Although the vehicle 20 may be an electric vehicle, the present disclosure is not limited to an electric motor system as a locomotive power source for the vehicle 20. Instead, other sources may be utilized to provide locomotive power to the vehicle 20. For example, locomotive power may be provided to the vehicle 20 by an internal combustion engine, a fuel cell, and / or a petroleum-based fuel engine. Locomotive power may be provided to the vehicle by a combination or hybrid system that may include an internal combustion engine, a battery unit, and / or an electric motor system. According to various examples, the vehicle 20 may be driver-controlled, semi-autonomous, fully autonomous, or any combination of user-controlled and automated. For example, a semi-autonomous example of the vehicle 20 may perform many or all commuting functions (e.g., increasing speed, decreasing speed, turning, signaling, etc.) independently of user interaction while the user maintains override control of the vehicle 20. The battery cooler 10 (also referred to as a heat exchanger 10) is disposed in an interior cabin of the vehicle 20.

[0046] refer to Figures 2 to 7B , the heat exchanger 10 generally includes a shell 12 (also referred to as a cooler body) and a lattice structure 14 (also referred to as a minimum surface structure 14) disposed in the shell 12. The shell 12 includes a first inlet 30 on a first end 32 of the shell 12 and a first outlet 34 on a second end 36 of the shell 12, wherein the first outlet 34 has a first annular structure 38 defining a first central opening 40. The shell 12 also includes: a second inlet 42 on the second end 36 of the shell 12, wherein the second inlet 42 is disposed through the first central opening 40 of the first outlet 34; and a second outlet 44 on the first end 32 of the shell 12, wherein the second outlet 44 has a second annular structure 46 defining a second central opening 48, and wherein the first inlet 30 is disposed through the second central opening 48 of the second outlet 44. The lattice structure 14 defines a first plurality of channels 50 and a second plurality of channels 52. The lattice structure 14 further defines a first conduit 54 in fluid communication with the first plurality of channels 50 and a second conduit 56 in fluid communication with the second plurality of channels 52 , wherein the first outlet 34 is in fluid communication with the first plurality of channels 50 of the lattice structure 14 and the second outlet 44 is in fluid communication with the second plurality of channels 52 of the lattice structure 14 .

[0047] refer to Figures 2 to 4, the housing 12 includes a first annular structure 38 on the second end 36 and a second annular structure 46 on the first end 32 (generally referred to as annular structures 38, 46) and a central housing portion 60. As shown, the central housing portion 60 has a cylindrical structure. The central housing portion 60 is not limited to a cylindrical structure, and according to other examples, may be configured as a rectangular parallelepiped or other prismatic structure. The central housing portion 60 generally intersects with the annular structures 38, 46 to form the housing 12. The central housing portion 60 may have a first tapered portion 62 intersecting with the first annular structure 38 and a second tapered portion 64 intersecting with the second annular structure 46.

[0048] The first tapered portion 62 and the second tapered portion 64 generally extend from the center housing portion 60 to the first annular structure 38 and the second annular structure 46, respectively. The first tapered portion 62 and the second tapered portion 64 may each have a generally conical or funnel shape. The first tapered portion 62 generally has a first diameter 70 and a second diameter 72 near the center housing portion 60, where the first tapered portion 62 intersects the first annular structure 38. Similarly, the second tapered portion 64 generally has a first diameter 66 and a second diameter 68 near the center housing portion 60, where the second tapered portion 64 intersects the second annular structure 46. The first diameters 66, 70 generally have diameters substantially similar to the center housing portion 60. The second diameters 68, 72 generally each have a diameter that is less than the diameter of the first annular structure 38 or the second annular structure 46. The second diameter 72 of the first tapered portion 62 may be substantially similar to the second diameter 68 of the second tapered portion 64. The second diameter 72 of the first tapered portion 62 may also be different from the second diameter 68 of the second tapered portion 64.

[0049] Still refer to Figures 2 to 4 And now also refer to Figure 5, the housing 12 may also include a first outlet 34 on the second end 36 of the housing 12 and a second outlet 44 on the first end 32 of the housing 12. The first outlet 34 is generally defined by a first annular structure 38, and the second outlet 44 is generally defined by a second annular structure 46. The annular structures 38, 46 are generally surfaces of revolution with a central opening or hole in the middle. The surface of revolution is generally defined by a shape having a periphery 80a, 80b that rotates around an axis of rotation 82. For example, a circle can be rotated around an axis of rotation to produce an annular structure, and specifically a circular ring structure. The shape having the periphery 80a, 80b can be a symmetrical shape, such as a circle, a square, or a rectangle, but can also be an asymmetrical shape. The first annular structure 38 is defined by a first periphery 80b that rotates around an axis 82. The first periphery 80b of the first annular structure defines a first central opening 40. Similarly, the second annular structure 46 is defined by a second periphery 80a that rotates around an axis of rotation 82. The second periphery 80a of the second annular structure 46 defines a second central opening 48.

[0050] The housing 12 also includes a first inlet 30 on a first end 32 of the housing 12 and a second inlet 42 on a second end 36 of the housing 12. The first inlet 30 generally extends from the second annular structure 46 and away from the housing 12. The first inlet 30 may extend along a rotational axis 82. The first inlet 30 has a first diameter 84 and may taper or narrow from a second diameter 86 as it extends away from the second annular structure 46. The second diameter 86 is defined at a location where the second annular structure 46 intersects the first inlet 30. The first diameter 84 may generally be the narrowest portion of the first inlet 30. Alternatively, the first inlet 30 may extend away from the housing 12 having just the first diameter 86.

[0051] Similarly, the second inlet 42 generally extends from the first annular structure 38 and away from the housing 12. The second inlet 42 can extend along the rotational axis 82. The second inlet 42 has a first diameter 88 and can taper or narrow to a second diameter 90 as it extends away from the first annular structure 38. The first diameter 88 is defined at the location where the first annular structure 38 intersects the second inlet 42. The second diameter 90 can generally be the narrowest portion of the second inlet 42. Alternatively, the second inlet 42 can extend away from the housing 12 having just the first diameter 88. The first diameter 84 of the first inlet 30 can be substantially equal to the first diameter 90 of the second inlet 42. The second diameter 86 of the first inlet 30 can also be substantially equal to the second diameter 88 of the second inlet 42.

[0052] Reference again Figures 2 to 4, the housing 12 may include a first outlet pipe 96, a second outlet pipe 98, and a bracket or mounting bracket 100. The first outlet pipe 96 and the second outlet pipe 98 are in fluid communication with the first outlet 34 and the second outlet 44, respectively. The first outlet pipe 96 and the second outlet pipe 98 may be coupled to a lower portion 102 of the first outlet 34 and a lower portion of the second outlet 44, respectively. This may allow gravity to assist in removing the first fluid 22 and the second fluid 24 from their respective outlets 34, 44. However, the first outlet pipe 96 and the second outlet pipe 98 are not limited to the lower portion 102, and may be coupled to the first outlet 34 and the second outlet 44 at other locations. Figure 4 As shown, the second outlet pipe 98 is routed from the second outlet 44 to the bracket 100. The first outlet pipe 96 is routed from the first outlet 34 to the bracket 100 along the lower surface 106 of the housing 12.

[0053] The first outlet pipe 96 and the second outlet pipe 98 may extend through the bracket 100 and may be configured to be coupled to a return line or pipe for a cooling system, as discussed below. The bracket 100 may be configured to be coupled to the vehicle 20, which may include a bracket disposed in the vehicle. The bracket 100 may generally support the heat exchanger 10. The bracket 100 may have a fastener hole 108, which may be used with a mechanical fastener (such as a bolt, a screw, a rivet or other permanent or semi-permanent fastener) to couple the heat exchanger 10 to the vehicle 20. Alternatively or additionally, the bracket 100 may be coupled to the vehicle 20 using a chemical fastener (such as an adhesive) or welding. The bracket 100 may be directly coupled to the housing 12 and may not be attached to the first outlet pipe 96 and the second outlet pipe 98. Additionally, the bracket 100 and the outlet pipes 96, 98 may have different configurations to fit the compartment or space within the vehicle 20. The heat exchanger 10 may also not include a mounting bracket 100 and the first outlet pipe 96 and the second outlet pipe 98.

[0054] refer to Figure 5 and Figure 6, the heat exchanger 10 includes a lattice structure 14 disposed within the interior 92 of the housing 12. The lattice structure 14 generally defines a first plurality of channels 50 and a second plurality of channels 52. The lattice structure 14 may be a periodic minimum surface structure or a tri-periodic surface structure having a first volume 116 and a second volume 118. The first volume 116 may be defined by the first plurality of channels 50, and the second volume 118 may be defined by the second plurality of channels 52. The periodic minimum surface may provide a larger shared surface area between the first volume 116 and the second volume 118 than other structures. The larger shared surface area of ​​the periodic minimum surface generally allows for more efficient heat transfer between the first volume 116 and the second volume 118. The first volume 116 and the second volume 118 may be substantially similar. The first volume 116 may be larger than the second volume 118, and vice versa. The unequal first volume 116 and the second volume 118 may illustrate the different heat capacities of the respective first fluid 22 and the second fluid 24 flowing therethrough, as discussed further below.

[0055] The lattice structure can be a three-periodic surface having a first volume 116 and a second volume 118. For example, the three-periodic surface can be a spiral icosahedron or a spiral icosahedron structure, which generally divides the volume into two relatively congruent irregular networks of passages or channels. The spiral icosahedron is a minimum surface with no intersections and an infinite three-period, and the structure can be approximated by the following equation: (sin[x]cos[y])+(sin[y]cos[z])+(sin[z]cos[x])=0, where x, y, and z are the coordinates of a point on a 3-dimensional graph with an x-axis, a y-axis, and a z-axis. The spiral icosahedron has a large surface area, and when the spiral icosahedron structure is incorporated into a heat exchanger, the structure allows a large amount of thermal contact between the fluids contained in the passages. When the lattice structure 14 is a spiral icosahedron structure, the first plurality of channels 50 and the second plurality of channels 52 can generally be two relatively congruent irregular networks of passages. The three-periodic surface is not limited to a spiral tetrahedron, and may be, in particular, a rhombus surface lattice or a Schwarz surface.

[0056] refer to Figure 5 and Figure 6 , the heat exchanger 10 may include a first inlet portion 120 and a second inlet portion 122 within the shell 12. The lattice structure 14 and the shell 12 define the first inlet portion 120 proximate the first end 32 of the shell 12 and the second inlet portion 122 proximate the second end 36 of the shell 12. The first inlet portion 120 includes the first inlet 30 and the first conduit 54, and the second inlet portion 122 includes the second inlet 42 and the second conduit 56.

[0057] The first conduit 54 is configured to distribute the first fluid 22 flowing from the first inlet 30 to the first plurality of channels 50. The first conduit 54 may be configured to evenly distribute the first fluid 22 evenly between the first plurality of channels 50. As shown, the first conduit 54 has a generally conical shape, and more specifically a conical shape with a rounded tip. However, the first conduit 54 is not limited to such a shape, and may have a cylindrical, spherical, cuboid, or other shapes configured to allow the first fluid 22 to flow from the first conduit 54 to the first plurality of channels 50. The first conduit 54 may have a first plurality of inlet orifices 124 to allow the first fluid 22 to flow between the first conduit 54 and the first plurality of channels 50. In other words, the first conduit 54 and the first plurality of channels 50 are fluidly connected through the first plurality of inlet orifices 124.

[0058] The first plurality of inlet orifices 124 may be defined by where the first conduits 54 intersect the lattice structure 14. The plurality of inlet orifices 124 may be defined by where the first conduits 54 intersect the first plurality of channels 50. The second plurality of channels 52 intersecting the first conduits 54 are typically blocked, blocked, or routed to the nearest second channel to maintain separation of the first volume 116 and the second volume 118 and prevent mixing of the first fluid 22 and the second fluid 24.

[0059] Similarly, the second conduit 56 is configured to distribute the second fluid 24 flowing from the second inlet 42 to the second plurality of channels 52. The second conduit 56 may be configured to evenly distribute the second fluid 24 evenly between the second plurality of channels 52. As shown, the second conduit 56 has a generally conical shape, and more specifically a conical shape with a rounded tip. However, the second conduit 56 is not limited to this shape, and may have a cylindrical, spherical, cuboid, or other shapes configured to allow the second fluid 24 to flow from the second conduit 56 to the second plurality of channels 52. The second conduit 56 may have a second plurality of inlet orifices 126 to allow the second fluid 24 to flow between the second conduit 56 and the second plurality of channels 52. In other words, the second conduit 56 and the second plurality of channels 52 are fluidically connected through the second plurality of inlet orifices 126.

[0060] The second plurality of inlet orifices 126 may be defined by the intersection of the second conduits 56 and the lattice structure 14. The plurality of inlet orifices 126 may be defined by the intersection of the second conduits 56 and the second plurality of channels 52. The first plurality of channels 50 intersecting the second conduits 56 are typically blocked, blocked, or routed to the nearest first channel to maintain separation of the first volume 116 and the second volume 118 and prevent mixing of the first fluid 22 and the second fluid 24.

[0061] Still refer to Figure 5 and Figure 6, the first outlet 34 and the second outlet 44 are generally in fluid communication with the first plurality of channels 50 and the second plurality of channels 52, respectively. The first plurality of outlet orifices 128 fluidly couple the first outlet 34 with the first plurality of channels 50, and the second plurality of outlet orifices 130 fluidly couple the second outlet 44 with the second plurality of channels 52. The first plurality of outlet orifices 128 are defined by the intersection of the first annular structure 38 with the first plurality of channels 50 of the lattice structure 14. The second plurality of channels 52, which may intersect the first annular structure 38, are generally blocked, blocked, or routed to the nearest second channel to maintain the separation of the first volume 116 and the second volume 118 and prevent the mixing of the first fluid 22 and the second fluid 24. The second plurality of outlet orifices 130 are defined by the intersection of the second annular structure 46 with the second plurality of channels 52 of the lattice structure 14. The first plurality of channels 50, which may intersect the second annular structure 46, are generally blocked, blocked, or routed to the nearest first channel to maintain the separation of the first volume 116 and the second volume 118 and prevent the mixing of the first fluid 22 and the second fluid 24.

[0062] Still refer to Figure 5 and Figure 6 , the heat exchanger defines a first flow path for the first fluid 22 (as indicated by arrow 140) and a second flow path for the second fluid 24 (as indicated by arrow 142). The first flow path 140 begins at the first inlet 30, passes through the first conduit 54, passes through the first plurality of inlet holes 124 to the first plurality of channels 50, passes through the first plurality of channels 50 to the first plurality of outlet orifices 128, and passes through the first plurality of outlet orifices 128 to the first outlet 34. The first flow path 140 may also include a flow from the first outlet 34 to the first outlet tube 96. When the first fluid 22 flows in the first conduit 54 along the first flow path 140, the first fluid 22 may be distributed to the first plurality of inlet orifices 124 to provide a substantially uniform and constant flow rate to each channel in the first plurality of channels 50. When the first fluid 22 flows along the first flow path 140, there may be a substantially uniform and constant flow rate from the first plurality of channels 50 to the first outlet 34.

[0063] The second flow path 142 begins at the second inlet 42, passes through the second conduit 56, passes through the second plurality of inlet apertures 126 to the second plurality of channels 52, passes through the second plurality of channels 52 to the second plurality of outlet apertures 130, and passes through the second plurality of outlet apertures 130 to the second outlet 44. The second flow path 142 may also include a flow from the second outlet 44 to the second outlet tube 98. As the second fluid 24 flows in the second conduit 56 along the second flow path 142, the second fluid 24 may be distributed to the second plurality of inlet apertures 126 to provide a substantially uniform and constant flow rate to each of the second plurality of channels 52. As the second fluid 24 flows along the second flow path 142, there may be a substantially uniform and constant flow rate from the second plurality of channels 52 to the second outlet 44. The first and second tapered portions 62, 64 of the housing, along with the lattice structure 14 along the tapered portions 62, 64, may help distribute the first flow path 140 and the second flow path 142 throughout the first volume 116 and the second volume 118. This distribution of the first flow path 140 and the second flow path 142 may facilitate heat exchange between the first fluid 22 and the second fluid 24 by reducing high flow portions and low flow portions on each flow path 140 , 142 .

[0064] refer to Fig. 7A and Figure 7B The heat exchanger 10 may be included in a cooling system provided in a vehicle, such as Fig. 7A As shown in one example of the embodiment, or in another example, included in a battery cooling system 150a, 150b provided in the vehicle 20, such as Figure 7B Cooling system 150a includes heat exchanger 10 coupled to heat source 152 and cooling source 154. Heat source 152 may be a battery pack, an internal combustion engine, a transmission, a computer or controller, or other heat source within vehicle 20. Cooling source 154 may be a refrigeration circuit, a radiator, or other cooling source within vehicle 20.

[0065] refer to Fig. 7A, the cooling system 150a is shown having a heat source 152 coupled to the first inlet 30 using a first tube or conduit 158. The first outlet 34 may be coupled to a first pump 160 using a second tube or conduit 162. The first pump 160 may be coupled to the heat source 152 using a third tube or conduit 164. Although the first pump 160 is depicted as being between the first outlet 34 of the heat exchanger 10 and the heat source 152, the first pump 160 may be located between the heat source 152 and the first inlet 30 of the heat exchanger 10 or may be integrated with the heat source 152. The first fluid circuit 166 of the cooling system 150a is defined by at least the first tube 158, the second tube 162, and the third tube 164, the heat source 152, the first volume 116 of the heat exchanger 10, and the first pump 160. The first pump 160 may be configured to circulate the first fluid 22 through the first fluid circuit 166.

[0066] The cooling source 154 is coupled to the second outlet 44 of the heat exchanger 10 with a fourth tube or conduit 168. The cooling source 154 is coupled to a second pump 170 with a fifth tube or conduit 172. The second pump 170 is coupled to the second inlet 42 with a sixth tube or conduit 174. Although the second pump 170 is depicted as being between the second inlet 42 of the heat exchanger 10 and the cooling source 154, the second pump 170 may be located between the cooling source 154 and the second outlet 44 of the heat exchanger 10 or may be integrated with the cooling source 154. A second fluid circuit 176 of the cooling system 150a is defined by at least the fourth tube 168, the fifth tube 172, and the sixth tube 174, the second volume 118 of the heat exchanger 10, and the second pump 170. The second pump 170 may be configured to circulate the second fluid 24 through the second fluid circuit 176.

[0067] When the first fluid 22 is circulated through the first fluid loop 166 by the first pump 160, the first fluid 22 leaves the heat source 152 at a high temperature and enters the heat exchanger 10. The first fluid 22 transfers heat or energy to the second fluid 24 that also flows through the heat exchanger 10, and leaves the heat exchanger 10 at a lower temperature than the first fluid 22 that entered. The first fluid 22 enters the heat source 152 and returns to the high temperature, and continues to circulate. When the second fluid 24 is circulated through the second fluid loop 176 by the second pump 170, the second fluid 24 leaves the cooling source at a low temperature and enters the heat exchanger 10. The second fluid 24 receives heat or energy from the first fluid 22 as it flows through the heat exchanger 10, and leaves the heat exchanger at a higher temperature than the first fluid 22 that entered. The second fluid 24 returns to the cooling source 154 and returns to the low temperature, and continues to circulate.

[0068] The first fluid 22 and the second fluid 24 may be liquid or gas when flowing through the respective first fluid circuit 166 or the second fluid circuit 176. The first fluid 22 and / or the second fluid 24 may undergo a phase change from liquid to gas and from gas to liquid when flowing in their respective fluid circuits 166, 176. In some examples, the first fluid 22 may be a coolant 22 and the second fluid 24 may be a refrigerant 24.

[0069] refer to Figure 7B , the cooling system 150b is shown as having a vehicle battery system as a heat source 152 and a refrigeration circuit as a second fluid circuit 176. The cooling source 154 can be part of a refrigeration system in which the heat exchanger is configured as an evaporator. In such an example, the second fluid 24 will be the refrigerant 24 flowing through the second fluid circuit 176. When the refrigerant 24 flows through the heat exchanger 10, the refrigerant 24 undergoes a phase change from liquid to gas, thereby removing heat or energy from the first fluid 22 flowing through the heat exchanger 10. The second fluid 24 returns to the cooling source 154 as a low-pressure gas. The compressor 180 of the cooling source 154 compresses the refrigerant 24 into a high-pressure gas. The compressor 180 can also be configured as a second pump 170 for the second fluid circuit 176. The refrigerant 24 as a high-pressure gas then flows from the compressor 180 to the condenser 182, where the refrigerant 24 phase changes to a high-pressure liquid. The refrigerant 24 then enters the expansion valve or capillary tube 184 and leaves as a low-pressure liquid. The refrigerant 24 then enters the heat exchanger 10, thereby repeating the cycle.A plurality of pipes or tubes 186 couple the various components of the second fluid circuit 176 together.

[0070] Reference again Figures 2 to 6 , the heat exchanger 10 can be manufactured using an additive manufacturing process. Typically, in an additive manufacturing process, digital three-dimensional design data is used to build a component in layers by depositing material on a build platform. Materials within a layer and materials of separate layers can be bonded or fused together by using a laser beam directed to points indicated by the computer-generated design data. Layers are added on top of each other and melted at predefined points to bond with previous layers.

[0071] The heat exchanger 10 can be formed or manufactured using any feasible additive manufacturing process, such as, but not limited to, extrusion additive manufacturing (e.g., fused filament manufacturing), photopolymerization additive manufacturing (e.g., stereolithography or SLA), powder bed fusion additive manufacturing, material jetting additive manufacturing, binder jetting additive manufacturing, directed energy deposition additive manufacturing, lamination additive manufacturing, and / or any combination thereof. In some cases, directed energy deposition additive manufacturing and powder bed fusion additive manufacturing allow the use of metals to produce objects. For example, metals such as stainless steel, titanium, aluminum, cobalt chromium alloys, steel, and / or any combination thereof can be used. By allowing the combined manufacture of the shell 12 and the lattice structure 14, the additive manufacturing process can be advantageous for forming the heat exchanger 10. The additive manufacturing process can also allow the creation or use of highly complex or intricate lattice structures 14 that would otherwise be impossible to produce. The heat exchanger 10 is not limited to such additive manufacturing processes.

[0072] Using the present device can provide a variety of advantages. For example, the heat exchanger 10 can provide efficient heat transfer between the first fluid 22 and the second fluid 24. The lattice structure 14 can provide a high surface area between the first volume 116 and the second volume 118 of the heat exchanger 10, thereby allowing more efficient heat transfer. In addition, efficient heat transfer can thereby provide more efficient cooling or remove more heat from the battery system or other heat source 152. In addition, the heat exchanger 10 can be used as an evaporator in a refrigeration circuit, thereby allowing the refrigeration circuit to cool the second fluid 24, which can be a coolant 24. In addition, the first flow path 140 and the second flow path 142 can provide a uniform distribution of the first fluid 22 and the second fluid 24 throughout the heat exchanger 10. The uniform distribution can also allow for more efficient heat transfer between the first fluid 22 and the second fluid 24. In addition, the first inlet 30 and the second inlet 42 of the central opening 40, 48 arranged through the first annular structure 38 and the second annular structure 46 can provide more efficient heat transfer with the first fluid 22 and the second fluid 24 due to the heat transfer between the first inlet 30 and the second inlet 42 and the first outlet 34 and the second outlet 44. Additional benefits or advantages of using the device may also be achieved and / or realized.

[0073] For purposes of this disclosure, the term "coupled" (in all its forms: coupled, coupled, coupled, etc.) generally refers to the joining of two components (electrical or mechanical) directly or indirectly to one another. Such connection may be fixed in nature or removable in nature. Such connection may be achieved with two components (electrical or mechanical) and any additional intermediate members may be integrally formed as a single unitary body with each other or with the two components. Unless otherwise specified, such connection may be permanent in nature or may be removable or releasable in nature.

[0074] In addition, any arranged parts that realize the same function are effectively "associated" so that the desired function is realized. Therefore, any two parts that are combined to realize a specific function herein can be regarded as "associated" with each other so that the desired function is realized, regardless of the architecture or intermediate parts. Similarly, any two parts so associated can also be regarded as "operably connected" or "operably connected" to each other to realize the desired function, and any two parts that can be so associated can also be regarded as "operably connected" to each other to realize the desired function. Some examples of operably connected include but are not limited to physically pairable and / or physically interactive parts and / or wirelessly interactive and / or wirelessly interactive parts and / or logically interactive and / or logically interactive parts. In addition, it should be understood that the parts preceded by the term "..." can be arranged in any feasible position (for example, arranged on a vehicle, in a vehicle, and / or outside a vehicle) so that the parts can work in any manner described herein.

[0075] It is also important to note that the construction and arrangement of the elements of the present invention as shown in the exemplary examples are merely illustrative. Although only several examples of the present innovation have been described in detail in the present disclosure, it will be readily understood by those skilled in the art who review the present disclosure that many modifications are possible (e.g., changes in the size, dimensions, structure, shape and proportion of various elements, the value of parameters, the mounting arrangement, the use of materials, colors, orientations, etc.) without substantially departing from the novel teachings and advantages of the narrated subject matter. For example, an element shown as being integrally formed may be composed of multiple parts, or an element shown as multiple parts may be integrally formed, the operation of the interface may be reversed or otherwise changed, the length or width of the structure and / or member or other elements of the connector or system may be changed, and the nature or number of adjustment positions provided between the elements may be changed. It should be noted that the elements and / or assemblies of the system may be composed of any of a variety of materials that provide sufficient strength or durability in any of a variety of colors, textures, and combinations. Therefore, all such modifications are intended to be included within the scope of the present innovation. Without departing from the spirit of the present innovation, other substitutions, modifications, changes, and omissions may be made in the design, working conditions, and arrangements of the desired and other exemplary examples.

[0076] Those skilled in the art and those who make or use the present disclosure will appreciate modifications of the present disclosure. Therefore, it should be understood that the embodiments shown in the drawings and described above are for illustrative purposes only and are not intended to limit the scope of the present disclosure as defined by the appended claims as interpreted according to patent law principles (including the doctrine of equivalents).

[0077] It should be understood that changes and modifications may be made to the foregoing constructions without departing from the concepts of the present disclosure, and it should be further understood that such concepts are intended to be covered by the appended claims unless the claims expressly state otherwise by their language.

[0078] According to the present invention, a heat exchanger for a vehicle is provided, the heat exchanger having: a shell; a coolant outlet, the coolant outlet being defined on a first end of the shell, wherein the coolant outlet has a first annular structure having a first central opening; a refrigerant outlet, the refrigerant outlet being defined on a second end of the shell, wherein the refrigerant outlet has a second annular structure having a second central opening; a coolant inlet, the coolant inlet being defined on the second end of the shell, wherein the coolant inlet is arranged through the second central opening of the refrigerant outlet; a refrigerant inlet, the refrigerant inlet being defined on the first end of the shell, wherein the refrigerant inlet is arranged through the first central opening of the coolant outlet; and a lattice structure provided in the shell, the lattice structure defining a plurality of coolant channels and a plurality of refrigerant channels, wherein the lattice structure defines a coolant conduit in fluid communication with the plurality of coolant channels and a refrigerant conduit in fluid communication with the plurality of refrigerant channels, and wherein the coolant outlet is in fluid communication with the plurality of coolant channels of the lattice structure, and the refrigerant outlet is in fluid communication with the plurality of refrigerant channels of the lattice structure.

[0079] According to an embodiment, the first annular structure of the coolant outlet is a first circular ring structure, and wherein the second annular structure of the refrigerant outlet is a second circular ring structure.

[0080] According to an embodiment, the lattice structure is a helical tetrahedron structure.

[0081] According to an embodiment, the housing has a central portion, a first tapered portion extending from the central portion and towards the first annular structure, and a second tapered portion extending from the central portion and towards the second annular structure.

[0082] According to an embodiment, the housing and the lattice structure consist of the same material.

[0083] According to an embodiment, the refrigerant flows along a refrigerant flow path, which is defined as from the refrigerant inlet, through the refrigerant conduit, through the plurality of refrigerant channels and to the refrigerant outlet, and wherein the coolant flows along a coolant flow path, which is defined as from the coolant inlet, through the coolant conduit, through the plurality of coolant channels and to the coolant outlet.

[0084] According to an embodiment, the refrigerant inlet and the refrigerant outlet are coupled to a refrigeration circuit, and wherein the coolant inlet and the coolant outlet are coupled to a vehicle battery system, and further wherein the refrigerant flows through the refrigeration circuit and the coolant flows through the vehicle battery system.

[0085] According to an embodiment, the invention is also characterized in that: the heat exchanger is configured as an evaporator of the refrigeration circuit.

[0086] According to an embodiment, the present invention is also characterized by: a coolant outlet pipe, which is connected to the first annular structure; and a refrigerant outlet pipe, which is connected to the second annular structure, wherein the refrigerant pipe is arranged along the bottom surface of the shell and close to the coolant outlet pipe.

[0087] According to an embodiment, the present invention is also characterized by a mounting bracket coupled to the housing, wherein the coolant outlet pipe and the refrigerant outlet pipe are routed through the mounting bracket.

[0088] According to the present invention, a heat exchanger for a vehicle battery system is provided, the heat exchanger having: a housing; a first inlet, the first inlet being on a first end of the housing; a first outlet, the first outlet being on a second end of the housing, wherein the first outlet has a first annular structure defining a first central opening; a second inlet, the second inlet being on the second end of the housing, wherein the second inlet is arranged through the first central opening of the first outlet; a second outlet, the second outlet being on the first end of the housing, wherein the second outlet has a second annular structure defining a second central opening, and wherein the first inlet is arranged through the second central opening of the second outlet; and a spiral icosahedron structure disposed in the housing, the spiral icosahedron structure defining a first plurality of channels and a second plurality of channels, wherein the spiral icosahedron structure defines a first inlet cone in fluid communication with the first inlet and a second inlet cone in fluid communication with the second inlet, and wherein a first flow path is defined from the first inlet of the housing, through the first inlet cone, through the first plurality of channels and to the first outlet, and further, wherein a second flow path is defined from the second inlet of the housing, through the second inlet cone, through the second plurality of channels and to the second outlet.

[0089] According to an embodiment, the first inlet and the first outlet are coupled to the vehicle battery system, and wherein the second inlet and the second outlet are coupled to a refrigeration circuit.

[0090] According to an embodiment, the heat exchanger is configured as an evaporator of the refrigeration circuit.

[0091] According to an embodiment, the present invention is also characterized by: a first outlet pipe, which is connected to the first annular structure; and a second outlet pipe, which is connected to the second annular structure, wherein the second pipe is arranged along the bottom surface of the shell and close to the first outlet pipe.

[0092] According to an embodiment, the present invention is also characterized by a support bracket coupled to the first outlet pipe and the second outlet pipe.

[0093] According to the present invention, a battery cooler for a vehicle battery system is provided, the battery cooler comprising: a shell, the shell comprising a first inlet, a second inlet opposite to the first inlet, a first outlet having a first annular structure surrounding the second inlet, and a second outlet having a second annular structure surrounding the first inlet; and a minimum surface structure arranged in the shell, the minimum surface structure defining a first plurality of channels and a second plurality of channels, wherein the minimum surface structure defines a first inlet conduit fluidly connected to the first inlet and the first plurality of channels and a second inlet conduit fluidly connected to the second inlet and the second plurality of channels, and wherein a first flow path is defined as from the first inlet, through the first inlet conduit, through the first plurality of channels and to the first outlet, and a second flow path is defined as from the second inlet, through the second inlet conduit, through the second plurality of channels and to the second outlet.

[0094] According to an embodiment, the minimum surface structure is a helical tetrahedron structure.

[0095] According to an embodiment, the first annular structure is a first circular ring structure and the second annular structure is a second circular ring structure.

[0096] According to an embodiment, the first inlet and the first outlet are coupled to the vehicle battery system, and the second inlet and the second outlet are coupled to a vehicle battery refrigeration system, and wherein the coolant flows along the first flow path through the vehicle battery system and returns to the first inlet, and further, wherein the refrigerant flows along the second flow path through the minimum surface structure and returns to the second inlet.

[0097] According to an embodiment, the present invention is also characterized by: a first outlet pipe, the first outlet pipe is connected to the first annular structure; a second outlet pipe, the second outlet pipe is connected to the second annular structure, wherein the second pipe is arranged along the bottom surface of the shell and close to the first outlet pipe; and a supporting bracket, the supporting bracket is connected to the first outlet pipe and the second outlet pipe.

Claims

1. A heat exchanger for a vehicle, the heat exchanger comprising: case; a coolant outlet defined on a first end of the housing, wherein the coolant outlet has a first annular structure having a first central opening; a refrigerant outlet defined on a second end of the shell, wherein the refrigerant outlet has a second annular structure having a second central opening; a coolant inlet defined on the second end of the housing, wherein the coolant inlet is disposed through the second central opening of the refrigerant outlet; a refrigerant inlet defined on the first end of the housing, wherein the refrigerant inlet is disposed through the first central opening of the coolant outlet; as well as a lattice structure disposed in the housing, the lattice structure defining a plurality of coolant channels and a plurality of refrigerant channels, wherein the lattice structure defines a coolant conduit in fluid communication with the plurality of coolant channels and a refrigerant conduit in fluid communication with the plurality of refrigerant channels, and wherein the coolant outlet is in fluid communication with the plurality of coolant channels of the lattice structure and the refrigerant outlet is in fluid communication with the plurality of refrigerant channels of the lattice structure. 2 . The heat exchanger of claim 1 , wherein the first annular structure of the coolant outlet is a first circular ring structure, and wherein the second annular structure of the refrigerant outlet is a second circular ring structure.

3. The heat exchanger of claim 1, wherein the lattice structure is a helical tetrahedron structure.

4. The heat exchanger of claim 1, wherein the housing has a central portion, a first tapered portion extending from the central portion and toward the first annular structure, and a second tapered portion extending from the central portion and toward the second annular structure.

5. The heat exchanger of claim 1, wherein the shell and the lattice structure are composed of the same material.

6. The heat exchanger of claim 1 , wherein the refrigerant flows along a refrigerant flow path defined as from the refrigerant inlet, through the refrigerant conduit, through the plurality of refrigerant channels, and to the refrigerant outlet, and wherein the coolant flows along a coolant flow path defined as from the coolant inlet, through the coolant conduit, through the plurality of coolant channels, and to the coolant outlet.

7. The heat exchanger of claim 6, wherein the refrigerant inlet and the refrigerant outlet are coupled to a refrigeration circuit, and wherein the coolant inlet and the coolant outlet are coupled to a vehicle battery system, and further wherein the refrigerant flows through the refrigeration circuit and the coolant flows through the vehicle battery system.

8. The heat exchanger of claim 7, wherein the heat exchanger is configured as an evaporator of the refrigeration circuit.

9. The heat exchanger according to any one of claims 1 to 8, further comprising: a coolant outlet pipe coupled to the first annular structure; as well as A refrigerant outlet pipe is coupled to the second annular structure, wherein the refrigerant pipe is arranged along a bottom surface of the shell and close to the coolant outlet pipe.

10. The heat exchanger according to claim 9, further comprising: A mounting bracket is coupled to the housing, wherein the coolant outlet pipe and the refrigerant outlet pipe are routed through the mounting bracket.

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