Advanced vehicle heat exchanger

Abstract

The invention provides an advanced vehicle heat exchanger. A heat exchanger includes a housing. A first cooling block is defined within the housing. The first cooling block includes a coolant inlet, a refrigerant inlet, and a first helical twenty-four-sided structure defining a first set of coolant channels and a first set of refrigerant channels. A second cooling block is defined within the housing. The second cooling block includes a coolant outlet, a refrigerant outlet, and a second helical twenty-four-surface structure defining a second set of coolant channels and a second set of refrigerant channels. A perforated barrier plate is interposed between the first cooling block and the second cooling block. The first set of coolant channels are in fluid communication with the second set of coolant channels via perforations in the barrier plate. The first set of refrigerant channels is in fluid communication with the second set of refrigerant channels via perforations in the barrier plate.

Description

Technical Field

[0001] The present disclosure relates generally to a heat exchanger, and more particularly, to a heat exchanger in a vehicle. Background Art

[0002] Consumers often compare available features and functionality between vehicles when making a purchasing decision. Therefore, there is a need for additional solutions that provide the features and functionality that consumers desire.

[0003] Energy storage systems such as battery electric vehicles (BEVs) or hybrid electric vehicles (HEVs) include multiple batteries electrically connected in parallel or in series. BEV or HEV batteries have specific temperature operating ranges that are critical to battery life and performance. Because battery charging or discharging may be exothermic, BEVs and HEVs are equipped with onboard cooling systems to keep the electric vehicle batteries within these operating ranges, depending on the battery composition and ambient temperature conditions. It is desirable to have a compact, efficient cooling system that minimizes the footprint of the onboard cooling system in BEVs and HEVs. Summary of the invention

[0004] According to a first aspect of the present disclosure, a heat exchanger is provided. The heat exchanger includes a shell and a first cooling block defined in the shell. The first cooling block includes a coolant inlet, a refrigerant inlet opposite to the coolant inlet, and a first spiral twenty-tetrahedron structure defining a first group of coolant channels and a first group of refrigerant channels. The second cooling block is defined in the shell. The second cooling block includes a coolant outlet, a refrigerant outlet opposite to the coolant outlet, and a second spiral twenty-tetrahedron structure defining a second group of coolant channels and a second group of refrigerant channels. The heat exchanger also includes a perforated baffle plate, which is inserted between the first cooling block and the second cooling block. The first group of coolant channels is fluidly connected to the second group of coolant channels via the perforations in the baffle plate, and the first group of refrigerant channels is fluidly connected to the second group of refrigerant channels via the perforations in the baffle plate.

[0005] Embodiments of the first aspect of the present disclosure may include any one or a combination of the following features:

[0006] - the coolant inlet further comprises a coolant introduction channel directing fluid flow into the first group of coolant channels, and the refrigerant inlet further comprises a refrigerant introduction channel directing fluid flow into the first group of refrigerant channels;

[0007] - the coolant outlet further comprises a coolant removal channel directing the fluid flow out of the second set of coolant channels, and the refrigerant outlet further comprises a refrigerant removal channel directing the fluid flow out of the second set of refrigerant channels;

[0008] - at least one of the coolant introduction channel and the refrigerant introduction channel is defined by a first spiral icosahedral structure, and at least one of the coolant removal channel and the refrigerant removal channel is defined by a second spiral icosahedral structure;

[0009] - the housing, the first helical icosahedron structure, the second helical icosahedron structure and the baffle are integrally connected;

[0010] - the first spiral tetrahedron structure defines a first conical recess near the coolant inlet and a second conical recess near the refrigerant inlet, the second conical recess extending toward the first conical recess;

[0011] - the second spiral tetrahedron structure defines a third conical recess near the coolant outlet and a fourth conical recess near the refrigerant outlet, the fourth conical recess extending toward the third conical recess;

[0012] - the coolant inlet and the coolant outlet are arranged on the front panel of the housing, and the refrigerant inlet and the refrigerant outlet are arranged on the rear panel of the housing; and

[0013] The coolant fluid is directed along a coolant path and the refrigerant fluid is directed along a refrigerant path, the refrigerant path being in a counter-flow configuration relative to the coolant path.

[0014] According to a second aspect of the present disclosure, a heat exchanger is provided. The heat exchanger includes a shell, a first cooling block defined in the shell. The first cooling block includes a coolant inlet and a refrigerant outlet opposite to the coolant inlet. The second cooling block is defined in the shell. The second cooling block includes a coolant outlet and a refrigerant inlet opposite to the coolant outlet. The heat exchanger also includes a first group of cooling channels and a first group of refrigerant channels defined in at least one of the first cooling block and the second cooling block, and a second group of cooling channels and a second group of refrigerant channels defined in at least one of the first cooling block and the second cooling block. The heat exchanger also includes a perforated baffle plate inserted between the first cooling block and the second cooling block, the first group of coolant channels being fluidly connected to the second group of coolant channels via the perforations in the baffle plate, and the first group of refrigerant channels being fluidly connected to the second group of refrigerant channels via the perforations in the baffle plate.

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

[0016] - the helical icosahedral structure defines at least one of a first group of coolant channels, a second group of coolant channels, a first group of refrigerant channels, and a second group of refrigerant channels;

[0017] - a first plurality of tubes is disposed in the first cooling block and a second plurality of tubes is disposed in the second cooling block, and the first plurality of tubes defines at least one of a first set of coolant channels and a second set of refrigerant channels, and the second plurality of tubes defines at least one of the second set of coolant channels and the first set of refrigerant channels;

[0018] - a first set of coolant channels extending through the first plurality of tubes and a second set of coolant channels defined by spaces between each tube of the first plurality of tubes, and a first set of coolant channels extending through the second plurality of tubes and a second set of coolant channels defined by spaces between each tube of the second plurality of tubes;

[0019] a coolant path that directs a coolant fluid through the first cooling block, across the baffle plate, and through the second cooling block; and a refrigerant path that directs a refrigerant fluid through the first cooling block, across the baffle plate, and through the second cooling block, wherein the refrigerant path directs the refrigerant fluid in a counter-current manner relative to the coolant fluid in the coolant path; and

[0020] The coolant inlet and the coolant outlet are arranged on the same side of the heat exchanger, and the refrigerant inlet and the refrigerant outlet are arranged on the same side of the heat exchanger.

[0021] According to a third aspect of the present disclosure, a heat exchanger is provided. The heat exchanger includes a shell and a first cooling block defined in the shell. The first cooling block includes a coolant inlet and a refrigerant outlet opposite to the coolant inlet. The second cooling block is defined in the shell. The second cooling block includes a coolant outlet and a refrigerant inlet opposite to the coolant outlet. The heat exchanger also includes: a perforated baffle plate inserted between the first cooling block and the second cooling block, the perforated baffle plate defining a plurality of perforations on opposite ends of the baffle plate; a first plurality of tubes disposed in the first cooling block, the first plurality of tubes guiding a coolant fluid from the coolant inlet to the plurality of perforations; and a second plurality of tubes disposed in the second cooling block, the second plurality of tubes guiding a refrigerant fluid from the refrigerant inlet to the plurality of perforations.

[0022] Embodiments of the third aspect of the present disclosure may include any one or a combination of the following features:

[0023] - the first plurality of tubes defines at least one of a first set of coolant channels and a second set of refrigerant channels, and the second plurality of tubes defines at least one of the second set of coolant channels and the first set of refrigerant channels;

[0024] - a first set of coolant channels extending through the first plurality of tubes and a second set of coolant channels defined by spaces between each tube of the first plurality of tubes, and a first set of coolant channels extending through the second plurality of tubes and a second set of coolant channels defined by spaces between each tube of the second plurality of tubes;

[0025] - a coolant introduction plate provided in the first cooling block, the coolant introduction plate being obliquely oriented and extending from the front panel of the housing to the rear panel of the housing; and a refrigerant introduction plate provided in the second cooling block, the refrigerant introduction plate being obliquely oriented and extending from the rear panel and toward the front panel; and

[0026] A first plurality of tubes are coupled to the coolant introduction plate and each of the first plurality of tubes comprises an inlet, each inlet being flush with the coolant introduction plate, and a second plurality of tubes are coupled to the refrigerant introduction plate and each of the second plurality of tubes comprises an inlet, each inlet being flush with the refrigerant introduction plate.

[0027] 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

[0028] In the attached picture:

[0029] Figure 1 is a perspective view of a vehicle according to one embodiment;

[0030] Figure 2 is a perspective view of a heat exchanger according to one embodiment;

[0031] Figure 3 is a perspective view of a heat exchanger having a helical icosahedral structure according to one embodiment;

[0032] Figure 4 is a top cross-sectional view of a heat exchanger having a first spiral icosahedron structure and a second spiral icosahedron structure according to one embodiment;

[0033] Figure 5 is a side cross-sectional view of a heat exchanger having a helical icosahedral structure and a conical recess according to one embodiment;

[0034] Figure 6 is a front cross-sectional view of a heat exchanger having a first spiral icosahedron structure, a second spiral icosahedron structure, and a baffle plate according to one embodiment;

[0035] Figure 7 is a top view of a heat exchanger having a coolant path and a refrigerant path traveling through a baffle according to one embodiment;

[0036] Figure 8 is a perspective view of a heat exchanger having a first plurality of tubes, a second plurality of tubes, and a baffle plate according to one embodiment;

[0037] Fig. 9is a top view of a heat exchanger having a first plurality of tubes, a second plurality of tubes, and a baffle plate according to one embodiment; and

[0038] Fig.10 is a top view of a heat exchanger having a coolant path and a refrigerant path running along a first plurality of tubes and a second plurality of tubes according to one embodiment. DETAILED DESCRIPTION

[0039] Reference will now be made in detail to the preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the various 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.

[0040] 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.

[0041] The presently illustrated embodiments reside primarily in a combination of method steps and apparatus components associated with a heat exchanger. Accordingly, apparatus components and method steps have been indicated 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 with details that are readily apparent to one of ordinary skill in the art having the benefit of the description herein. In addition, like reference numerals in the specification and drawings represent like elements.

[0042] 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.

[0043] In this document, relational terms (such as first and second, top and bottom, etc.) are used only to distinguish one entity or action from another entity or action, and do not necessarily require or imply 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 inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements, but may 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 that includes the element.

[0044] As used herein, the term "about" means that the amount, size, formula, parameter and other quantity and characteristics are not exact, nor need to be exact, but may 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. Whether or not 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 of the ranges are significant in relation to the other endpoint and independently of the other endpoint.

[0045] 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 indicate 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.

[0046] 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.

[0047] As used herein, the term "refrigerant" refers to a fluid used in a refrigeration cycle used in an air conditioning or heat pump system. The refrigerant fluid may be a phase change fluid such that the fluid condenses into a liquid when cooled during the refrigeration cycle and is heated to a gas when heated during the refrigeration cycle.

[0048] As used herein, the term "coolant" refers to a fluid that is cooled in order to remove or dissipate heat from an object or system.

[0049] As used herein, the term "counterflow" refers to a heat exchanger geometry that uses at least two paths and maximizes the temperature gradient between at least two fluids in a heat exchanger cavity by operating the flow paths in anti-parallel directions.

[0050] As used herein, the phrase "manufactured as a single piece" refers to a device that is manufactured in a process that forms a single unified component or piece that is integrally cast or manufactured without requiring separate manufacturing processes to form multiple pieces that are subsequently joined together.

[0051] Reference now Figure 1 , depicts a vehicle 12 including a body 14 and a drive unit 16. In aspects where the vehicle 12 is configured as a battery electric vehicle (BEV) or a hybrid electric vehicle (HEV), the drive unit 16 of the vehicle 12 may include a battery system 18. The battery system 18 is in electrical communication with the drive unit 16 of the vehicle 12, such as one or more electric motors mechanically coupled to wheels of the vehicle 12. The drive unit 16 of the vehicle 12 may additionally or alternatively include an internal combustion engine (ICE) or a fuel cell to provide operating power for the vehicle 12.

[0052] When the battery system 18 provides power to the drive unit 16, it may be desirable to deliver coolant to the battery system 18 using the cooling system 20 to maintain the operating temperature of the battery system 18. Specifically, the cooling system 20 may include one or more heat exchangers 10 to efficiently transfer heat from the coolant fluid to the refrigerant fluid.

[0053] refer to Figures 1 to 7 , the vehicle 12 includes a heat exchanger 10. The heat exchanger 10 includes a housing 30 and a first cooling block 32 defined within the housing 30. The first cooling block 32 includes a coolant inlet 34, a refrigerant inlet 36 opposite the coolant inlet 34, and a first spiral icosahedron structure 38 defining a first group of coolant channels 40 and a first group of refrigerant channels 42. A second cooling block 44 is also defined within the housing 30. The second cooling block 44 includes a coolant outlet 46, a refrigerant outlet 48 opposite the coolant outlet 46, and a second spiral icosahedron structure 50 defining a second group of coolant channels 52 and a second group of refrigerant channels 54. A perforated baffle plate 56 is interposed between the first cooling block 32 and the second cooling block 44. The first group of coolant channels 40 are in fluid communication with the second group of coolant channels 52 via perforations in the baffle plate 56. The first group of refrigerant channels 42 are in fluid communication with the second group of refrigerant channels 54 via perforations in the baffle plate 56.

[0054] refer to Figures 1 to 10 , the heat exchanger 10 includes a housing 30. The housing 30 includes a front panel 60, a rear panel 62 opposite to the front panel 60, a bottom panel 64 and a top panel 66 extending between the front panel 60 and the rear panel 62, and a first side panel 68 and a second side panel 70 opposite to the first side panel 68. According to various aspects, the housing 30 can define one of various shapes, such as a quadrilateral shape, a circular shape, and / or one of various other shapes. According to various aspects, the housing 30 is configured to enclose various components of the heat exchanger 10, as provided herein.

[0055] refer to Figures 1 to 10 , the shell 30 of the heat exchanger 10 can be manufactured in an additive manufacturing process that manufactures additional components of the heat exchanger 10. In other embodiments, the shell 30 of the heat exchanger 10 can be manufactured in a separate manufacturing process, where the first cooling block 32, the second cooling block 44 and the baffle plate 56 are attached to the shell 30.

[0056] refer to Figure 7 and Fig.10 , the housing 30 has a structure that defines at least one coolant path 72 and at least one refrigerant path 74. The coolant path 72 and the refrigerant path 74 are thermally connected so that the fluid in the coolant path 72 can transfer heat to the fluid in the refrigerant path 74, thereby heating the fluid in the refrigerant path 74 and cooling the fluid in the coolant path 72, as provided herein.

[0057] refer to Figures 2 to 10 , the housing 30 includes a baffle 56 disposed within the housing 30. In some examples, the baffle 56 extends across the width and / or depth of the housing 30. For example, the baffle 56 can extend from the front panel 60 to the rear panel 62 of the housing 30, such that the first cooling block 32 and the second cooling block 44 are defined within the housing 30, wherein the two cooling blocks 32, 44 are separated by the baffle 56. The baffle 56 can be integrally formed in the same machining or manufacturing process as the first cooling block 32 and / or the second cooling block 44. Alternatively, the baffle 56 can be made in a separate machining or manufacturing process so that it is physically attached to the first cooling block 32 and / or the second cooling block 44 in a subsequent step.

[0058] Reference again Figures 2 to 7, the shell 30 can surround one or more spiral 24-hedron structures. In some examples, the shell 30 can enclose the first spiral 24-hedron structure 38 in the first cooling block 32 and the second spiral 24-hedron structure 50 in the second cooling block 44. As used herein, the spiral 24-hedron structure is a three-dimensional lattice that forms at least two interpenetrating mazes. The body of the spiral 24-hedron structure (defined as a channel that is not constrained by the heat exchanger shell 30 or the baffle 56) is a minimal surface with no intersection and infinite triple periodicity. The body of the spiral 24-hedron structure has a structure that 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 helicoidal icosahedron has a large surface area to volume ratio and when incorporated into a heat exchanger, the helicoidal icosahedron structure allows for a large amount of thermal contact between fluids contained within the channels.

[0059] exist Figures 2 to 7 In the illustrated embodiment, the housing 30 includes a coolant inlet 34 and a refrigerant inlet 36. The coolant inlet 34 is intended to guide the coolant fluid into the first cooling block 32, and the refrigerant inlet 36 is intended to guide the refrigerant fluid into the first cooling block 32, wherein the introduction of the refrigerant fluid can be substantially countercurrent relative to the coolant fluid. In some aspects, both the coolant inlet 34 and the refrigerant inlet 36 are coupled to the housing 30. For example, the coolant inlet 34 and the refrigerant inlet 36 can be coupled to opposite sides of the housing 30, which allows countercurrent, wherein the refrigerant fluid flows in a direction opposite to the coolant fluid. In addition, although the coolant inlet 34 and the refrigerant inlet 36 can be arranged at a place where the inlet fluid flow is perpendicular to the housing 30, it is also conceivable that the coolant inlet 34 and / or the refrigerant inlet 36 can also form an acute angle between the surfaces of the inlets 34, 36 and the housing 30.

[0060] exist Figures 2 to 7In the illustrated embodiment, the first cooling block 32 includes a coolant introduction channel 80 in fluid communication with the coolant inlet 34. In some embodiments, the first spiral 24-hedron structure 38 defines the coolant introduction channel 80. In such embodiments, the first spiral 24-hedron structure 38 can define one of a variety of shapes, which in turn define the coolant introduction channel 80. For example, the first spiral 24-hedron structure 38 can define a conical recess 82, wherein the coolant introduction channel 80 is defined along the outer periphery of the conical recess 82. According to various aspects, the coolant introduction channel 80 has a cross-section that is smaller than the cross-section of the coolant inlet 34. In other aspects, the coolant introduction channel 80 can have a cross-section that is larger than the first group of coolant channels 40. The coolant introduction channel 80 is in fluid communication with the coolant inlet 34 and the first group of coolant channels 40, so that the coolant fluid can flow from the coolant inlet 34 to the first group of coolant channels 40. Additionally, it is generally contemplated that the coolant introduction passage 80 may have a shape defined by an interface of the coolant introduction passage 80 with the first set of coolant passages 40 , and wherein the interface may at least partially determine a flow rate of coolant fluid into the first set of coolant passages 40 .

[0061] exist Figures 2 to 7 In the illustrated embodiment, the first cooling block 32 includes a refrigerant introduction channel 90 in fluid communication with the refrigerant inlet 36. In some embodiments, the first spiral icosahedron structure 38 defines the refrigerant introduction channel 90. In such embodiments, the first spiral icosahedron structure 38 may define one of a variety of shapes, which in turn define the refrigerant introduction channel 90. For example, the first spiral icosahedron structure 38 may define a conical recess 82, wherein the refrigerant introduction channel 90 is defined along the outer periphery of the conical recess 82. In such aspects, the conical recess 82 may have a different shape and / or size than the conical recess that at least partially defines the coolant introduction channel 80. According to various aspects, the refrigerant introduction channel 90 has a cross-section that is smaller than the cross-section of the refrigerant inlet 36. In other aspects, the refrigerant introduction channel 90 may have a cross-section that is larger than the first group of refrigerant channels 42. The refrigerant introduction channel 90 is in fluid communication with the refrigerant inlet 36 and the first group of refrigerant channels 42, so that the refrigerant fluid can flow from the refrigerant inlet 36 to the first group of refrigerant channels 42. Additionally, it is generally contemplated that the refrigerant inlet passage 90 may have a shape defined by an interface of the refrigerant inlet passage 90 with the first set of refrigerant passages 42 , and wherein the interface may at least partially determine a flow rate of the refrigerant fluid entering the first set of refrigerant passages 42 .

[0062] refer to Figures 3 to 7, a first group of coolant channels 40 are defined in the first cooling block 32. In some examples, the first group of coolant channels 40 extend from the coolant inlet 34 and toward the refrigerant inlet 36. In various aspects, the first spiral icosahedral structure 38 defines the first group of coolant channels 40. In such aspects, the first group of coolant channels 40 can be in direct fluid communication with the coolant inlet 34, or the first group of coolant channels 40 can be in fluid communication with the coolant inlet 34 via a coolant introduction channel 80.

[0063] Reference again Figures 3 to 7 , a first group of refrigerant channels 42 are defined in the first cooling block 32. In some examples, the first group of refrigerant channels 42 extend from the refrigerant inlet 36 and toward the coolant inlet 34. In various aspects, the first spiral icosahedral structure 38 defines the first group of refrigerant channels 42. In such aspects, the first group of refrigerant channels 42 can be in direct fluid communication with the refrigerant inlet 36, or the first group of refrigerant channels 42 can be in fluid communication with the refrigerant inlet 36 via a refrigerant introduction channel 90.

[0064] like Figures 2 to 7 As shown, the first group of coolant channels 40 is in thermal communication with the first group of refrigerant channels 42. The interpenetrating maze-like network of first spiral icosahedral structures 38 defining the first group of coolant channels 40 and the first group of refrigerant channels 42 has a large surface area that promotes heat transfer from the cooling fluid contained within the first group of coolant channels 40 to the refrigerant fluid contained within the first group of refrigerant channels 42, thereby cooling the coolant.

[0065] According to various aspects, the first group of coolant channels 40 can extend from the coolant inlet 34 to a first plurality of perforations 100 defined on an end of the baffle plate 56, and the first group of refrigerant channels 42 can extend from the refrigerant inlet 36 to a second plurality of perforations 102 defined on an opposite end of the baffle plate 56. The first plurality of perforations 100 and the second plurality of perforations 102 can allow coolant fluid and refrigerant fluid to flow through the baffle plate 56 and into the second cooling block 44. In such aspects, the coolant fluid within the first group of coolant channels 40 can flow into the second group of coolant channels 52, and the refrigerant fluid within the first group of refrigerant channels 42 can flow into the second group of refrigerant channels 54, as provided herein.

[0066] The size and number of perforations in the baffle plate 56 will vary depending on the desired flow characteristics. In some embodiments, the perforation size and geometry will match the coolant channels 40, 52 and refrigerant channels 42, 54 coupled to the baffle plate 56. In some embodiments, the number of perforations on the baffle plate 56 will be the same for the coolant path 72 as for the refrigerant path 74. In other embodiments, the number of perforations on the baffle plate 56 may be unequal, such that there are more perforations in the baffle plate 56 for transferring coolant fluid from the first set of coolant channels 40 to the second set of coolant channels 52 than there are perforations in the baffle plate 56 for transferring refrigerant from the first set of refrigerant channels 42 to the second set of refrigerant channels 54. In some embodiments, the number of perforations on the baffle plate 56 may be unequal such that there are more perforations in the baffle plate 56 for transferring refrigerant fluid from the first group of refrigerant channels 42 to the second group of refrigerant channels 54 than there are perforations in the baffle plate 56 for transferring coolant from the first group of coolant channels 40 to the second group of coolant channels 52.

[0067] Reference again Figures 3 to 7 , a second set of coolant channels 52 are defined in the second cooling block 44. In some examples, the second set of coolant channels 52 extend from the first plurality of perforations 100 near the refrigerant outlet 48 and toward the coolant outlet 46. In various aspects, the second spiral icosahedral structure 50 defines a second set of coolant channels 52. In such aspects, the second set of coolant channels 52 can be in direct fluid communication with the coolant outlet 46, or the second set of coolant channels 52 can be in fluid communication with the coolant outlet 46 via the coolant removal channel 110.

[0068] A second group of refrigerant channels 54 are defined in the second cooling block 44. In some examples, the second group of refrigerant channels 54 extend from the second plurality of perforations 102 near the coolant outlet 46 and toward the refrigerant outlet 48. In various aspects, the second spiral icosahedral structure 50 defines a second group of refrigerant channels 54. In such aspects, the refrigerant fluid in the second group of refrigerant channels 54 can flow parallel, countercurrently, or obliquely relative to the coolant flow in the second group of coolant channels 52. The second group of refrigerant channels 54 can be in direct fluid communication with the refrigerant outlet 48, or the second group of refrigerant channels 54 can be in fluid communication with the refrigerant outlet 48 via a refrigerant removal channel 120.

[0069] like Figures 4 to 7As shown, the second group of coolant channels 52 is in thermal communication with the second group of refrigerant channels 54. The interpenetrating maze-like network of spiral tetrahedral structures defining the second group of coolant channels 52 and the second group of refrigerant channels 54 has a large surface area that promotes heat transfer from the cooling fluid contained in the second group of coolant channels 52 to the refrigerant fluid contained in the refrigerant channels 54, thereby cooling the coolant.

[0070] exist Figures 4 to 7 In the illustrated embodiment, the second cooling block 44 includes a coolant removal channel 110 in fluid communication with the coolant outlet 46. In some embodiments, the second spiral 24-hedron structure 50 defines the coolant removal channel 110. In such embodiments, the second spiral 24-hedron structure 50 can define one of a variety of shapes, which in turn define the coolant removal channel 110. For example, the second spiral 24-hedron structure 50 can define a conical recess 82, wherein the coolant removal channel 110 is defined along the outer periphery of the conical recess 82. According to various aspects, the coolant outlet 46 has a cross-sectional value greater than the cross-sectional value of the second group of coolant channels 52. The transition of the coolant flow can be achieved via the coolant removal channel 110, which has one or more cross-sectional values ​​intermediate between the cross-sectional values ​​of the coolant outlet 46 and the second group of coolant channels 52, and is disposed between the coolant outlet 46 and the second group of coolant channels 52. In some embodiments, the coolant removal channel 110 is configured to transition the coolant fluid flow from the second group of coolant channels 52 to the coolant outlet 46. Additionally, it is generally contemplated that the coolant removal passage 110 may have a shape defined by an interface of the coolant removal passage 110 with the second set of coolant passages 52 , and wherein the interface may at least partially determine a flow rate of coolant fluid out of the second set of coolant passages 52 .

[0071] exist Figures 4 to 7In the illustrated embodiment, the second cooling block 44 includes a refrigerant removal channel 120 in fluid communication with the refrigerant outlet 48. In some embodiments, the second spiral 24-hedron structure 50 defines the refrigerant removal channel 120. In such embodiments, the second spiral 24-hedron structure 50 can define one of a variety of shapes, which in turn define the refrigerant removal channel 120. For example, the second spiral 24-hedron structure 50 can define a conical recess 82, wherein the refrigerant removal channel 120 is defined along the outer periphery of the conical recess 82. According to various aspects, the refrigerant outlet 48 has a cross-sectional value greater than the cross-sectional value of the second group of refrigerant channels 54. The transition of the refrigerant flow can be achieved via the refrigerant removal channel 120, which has one or more cross-sectional values ​​intermediate between the cross-sectional values ​​of the refrigerant outlet 48 and the second group of refrigerant channels 54, and is disposed between the refrigerant outlet 48 and the second group of refrigerant channels 54. In some embodiments, the refrigerant removal channel 120 is configured to transition the refrigerant fluid flow from the second group of refrigerant channels 54 to the refrigerant outlet 48. Additionally, it is generally contemplated that the refrigerant removal passage 120 may have a shape defined by an interface of the refrigerant removal passage 120 with the second set of refrigerant passages 54 , and wherein the interface may at least partially determine a flow rate of the refrigerant fluid out of the second set of refrigerant passages 54 .

[0072] According to various aspects, it is generally contemplated that the heat exchanger 10 may include one or more conical recesses 82 defining the introduction passages 80, 90 and the removal passages 110, 120. For example, the first spiral icosahedral structure 38 may define a first conical recess 82a defining the coolant introduction passage 80 and a second conical recess 82b defining the refrigerant introduction passage 90, wherein the second conical recess 82b is opposite to the first conical recess 82a and extends toward the first conical recess 82a. Similarly, the second gyroscopic structure 50 may define a third conical recess 82c defining the coolant removal passage 110 and a fourth conical recess 82d defining the refrigerant removal passage 120, wherein the fourth conical recess 82d is opposite to the third conical recess 82c and extends toward the third conical recess 82c. In addition, it is also contemplated that each conical recess 82a, 82b, 82c, and 82d may define a shape and / or depth that is consistent with or different from each conical recess 82a, 82b, 82c, and 82d. For example, the first conical recess 82a and the third conical recess 82c may have a greater depth into each spiral tetrahedral structure 38, 50 than the second conical recess 82b and the fourth conical recess 82d. In such an example, the greater depth of the first conical recess 82a and the third conical recess 82c may increase the rate of increase of the coolant flow relative to the rate of the refrigerant flow.

[0073] Reference now Figures 3 to 7 , the heat exchanger 10 includes a coolant outlet 46 and a refrigerant outlet 48. The coolant outlet 46 is intended to guide the coolant fluid out of the second cooling block 44, and the refrigerant outlet 48 is intended to guide the refrigerant fluid out of the second cooling block 44, wherein the refrigerant fluid can be substantially countercurrent relative to the coolant fluid. In some aspects, both the coolant outlet 46 and the refrigerant outlet 48 are connected to the shell 30. For example, the coolant outlet 46 and the refrigerant outlet 48 can be connected to opposite sides of the shell 30, which allows countercurrent, wherein the refrigerant fluid flows in a direction opposite to the coolant fluid. In addition, although the coolant outlet 46 and the refrigerant outlet 48 can be arranged at a place where the outlets 46, 48 guide the fluid flow perpendicular to the shell 30. It is also conceivable that the coolant outlet 46 and / or the refrigerant outlet 48 can also form an acute angle between the surfaces of the outlets 46, 48 and the shell 30.

[0074] Reference now Figure 7 , the coolant path 72 of the heat exchanger 10 generally directs the coolant fluid through the heat exchanger 10. Specifically, the coolant path 72 can direct the coolant fluid from the coolant inlet 34 through the coolant introduction channel 80 and into the first set of coolant channels 40. The coolant path 72 then directs the coolant fluid through the first plurality of perforations 100 and into the second set of coolant channels 52. The coolant fluid is then directed to the coolant removal channel 110 and out the coolant outlet 46.

[0075] Reference again Figure 7 , the refrigerant path 74 of the heat exchanger 10 generally directs the refrigerant fluid through the heat exchanger 10. Specifically, the refrigerant path 74 can direct the refrigerant fluid from the refrigerant inlet 36 through the refrigerant introduction passage 90 and into the first set of refrigerant passages 42. The refrigerant path 74 then directs the refrigerant fluid through the second plurality of perforations 102 and into the second set of refrigerant passages 54. The refrigerant fluid is then directed to the refrigerant removal passage 120 and out the refrigerant outlet 48.

[0076] like Figure 7 As shown, the coolant path 72 can be in a counter-flow configuration relative to the refrigerant path 74. This counter-flow allows heat transfer to occur between the coolant fluid and the refrigerant fluid. In some embodiments, the coolant flow can be reversed so that the coolant fluid flows through the coolant outlet 46, through the second set of coolant channels 52, through the baffle 56, through the coolant introduction channel 80 to the first set of coolant channels 40, and out of the coolant inlet 34. This alternative coolant path will allow for a parallel flow configuration.

[0077] refer to Figures 1 to 7, the heat exchanger 10 can be manufactured by an additive manufacturing process, in which continuous layers of one or more materials are arranged on top of each other to "build" a three-dimensional component layer by layer. The continuous layers are usually fused together to form an integral component. In some embodiments, the housing 30, the first cooling block 32, the baffle 56, and the second cooling block 44 are all made by the same additive manufacturing process. In other embodiments, other manufacturing methods known in the art are possible, such as a layer-increasing process, a layer-reducing process, or a hybrid process. In some embodiments, the heat exchanger 10 can be manufactured by a combination of these processes. In some embodiments, the heat exchanger 10 is manufactured by combining an additive manufacturing process with a layer-increasing process, a layer-reducing process, or a hybrid process. In some embodiments, the heat exchanger 10 is manufactured by additively manufacturing one part of the heat exchanger 10 while using a machining process (such as electrical discharge machining) to manufacture another part of the heat exchanger 10. According to various aspects, the heat exchanger 10 can be made of any thermally conductive material (such as a metal). Ideal metals for use as heat exchanger materials may include nickel, nickel alloys, cobalt, cobalt alloys, chromium-molybdenum, titanium, aluminum, aluminum alloys, or combinations thereof.

[0078] Reference now Figures 8 to 10 , the heat exchanger 10 can include a first plurality of tubes 130 within the first cooling block 32 and a second plurality of tubes 132 in the second cooling block 44. According to various aspects, the coolant inlet 34 can be in fluid communication with the first plurality of tubes 130, and the refrigerant inlet 36 can be in fluid communication with the second plurality of tubes 132. In such aspects, the first plurality of tubes 130 is configured to direct the flow of coolant fluid from the coolant inlet 34 along the first cooling block 32 and into the second cooling block 44, and the second plurality of tubes 132 is configured to direct the flow of refrigerant fluid from the refrigerant inlet 36 through the second cooling block 44 and into the first cooling block 32, as provided herein.

[0079] Further references Figures 8 to 10, the first plurality of tubes 130 may be disposed within the first cooling block 32. In some examples, the first plurality of tubes 130 may be disposed within the first cooling block 32 such that the coolant inlet 140 of the first plurality of tubes 130 is proximate to the coolant inlet 34 and the coolant outlet 142 of the first plurality of tubes 130 is adjacent to the baffle plate 56 and substantially aligned with the first plurality of perforations 100. According to various aspects, each tube in the first plurality of tubes 130 may include a first segment 144 extending away from the coolant inlet 34, a bend 146 at an end of the first segment 144, and a second segment 148 extending away from the bend 146 and toward the baffle plate 56. Each tube in the first plurality of tubes 130 may have a shape and / or length that is consistent with or different from each other tube in the first plurality of tubes 130. For example, each tube 130 may be offset from one another so that each tube 130 has substantially the same length and size. According to various aspects, the first plurality of tubes 130 are configured to define a first set of coolant channels 40 that direct coolant fluid away from the coolant inlet 34 and toward a first plurality of perforations defined on the baffle plate 56 .

[0080] Reference now Figure 8 and Fig. 9 , the heat exchanger 10 may include a coolant introduction plate 150 disposed within the first cooling block 32. The coolant introduction plate 150 may be coupled to the bottom panel 64 and the top panel 66 of the housing 30. In some examples, the coolant introduction plate 150 may be oriented obliquely in the first cooling block 32 so that the coolant introduction plate 150 abuts the sidewalls and the baffle plate 56 of the housing 30. In such examples, the 150 degree orientation of the coolant introduction plate may be at least partially consistent with the alignment of the first plurality of tubes 130. For example, each tube in the first plurality of tubes 130 may be coupled to the coolant introduction plate 150 so that the inlet 140 of the first plurality of tubes 130 protrudes from the coolant introduction plate 150, is flush with the coolant introduction plate, or is recessed into the coolant introduction plate. According to various aspects, the coolant introduction plate 150 is configured to define a coolant inlet flow chamber 152 that allows the coolant fluid to flow uniformly into the first plurality of tubes 130. In such aspects, the coolant inlet flow chamber 152 can define one of a variety of shapes, such as triangular, circular, prismatic, and / or one of a variety of other shapes that allow coolant to flow into the first cooling block 32 and the first plurality of tubes 130. In still other aspects, the coolant introduction plate 150 can function as a barrier that redirects the refrigerant fluid toward the refrigerant outlet 48 as the refrigerant fluid passes through the second plurality of perforations 102, as provided herein.

[0081] Further references Figures 8 to 10, the second plurality of tubes 132 can be disposed within the second cooling block 44. In some examples, the second plurality of tubes 132 can be disposed within the second cooling block 44 such that an inlet 160 of the second plurality of tubes 132 is proximate to the refrigerant inlet 36 and an outlet 162 of the second plurality of tubes 132 is adjacent to the baffle plate 56 and substantially aligned with the second plurality of perforations 102. According to various aspects, each tube of the second plurality of tubes 132 can include a first segment 164 extending away from the refrigerant inlet 36, a bend 166 at an end of the first segment 164, and a second segment 168 extending away from the bend 166 and toward the baffle plate 56. Figure 8 and Fig. 9 As shown, the second plurality of tubes 132 can be disposed in the second cooling block 44 and are mirrored, parallel, inverted, or in another configuration relative to the first plurality of tubes 130. Each tube in the second plurality of tubes 132 can have a shape and / or length that is consistent with or different from each other tube in the second plurality of tubes 132. For example, each tube 132 can be offset from one another so that each tube 132 has approximately the same length and size. According to various aspects, the second plurality of tubes 132 is configured to define a first set of refrigerant channels 42 that direct the coolant fluid away from the coolant inlet 34 and toward the first plurality of perforations 100 defined on the baffle plate 56.

[0082] Reference now Figure 8 and Fig. 9 , the heat exchanger 10 may include a refrigerant introduction plate 170 disposed within the second cooling block 44. The refrigerant introduction plate 170 may be coupled to the bottom panel 64 and the top panel 66 of the shell 30. In some examples, the refrigerant introduction plate 170 may be oriented obliquely in the second cooling block 44 so that the refrigerant introduction plate 170 abuts the sidewalls and the baffle plate 56 of the shell 30. In such examples, the 170 degree orientation of the refrigerant introduction plate may be at least partially consistent with the alignment of the second plurality of tubes 132. For example, each tube 132 in the second plurality of tubes 132 may be coupled to the refrigerant introduction plate 170 so that the inlet 160 of the second plurality of tubes 132 protrudes from the refrigerant introduction plate 170, is flush with the refrigerant introduction plate, or is recessed into the refrigerant introduction plate. According to various aspects, the refrigerant introduction plate 170 is configured to define a refrigerant inlet flow chamber 172 that allows the refrigerant fluid to flow uniformly into the second plurality of tubes 132. In such aspects, the refrigerant inlet flow chamber 172 can define one of a variety of shapes, such as triangular, circular, prismatic, and / or one of other various shapes that allow refrigerant to flow into the second cooling block 44 and the second plurality of tubes 132. In still other aspects, the refrigerant introduction plate 170 can function as a barrier that redirects the coolant fluid toward the coolant outlet 46 as the coolant fluid passes through the first plurality of perforations 100, as provided herein.

[0083] Reference now Fig.10 , the coolant path 72 directs the coolant fluid through the heat exchanger 10. Specifically, the coolant path 72 directs the coolant fluid through the coolant inlet 34 and into the coolant inlet flow chamber 152, wherein the coolant fluid is directed into the inlet 140 of the first plurality of tubes 130. The coolant fluid then travels through the first plurality of tubes 130 and the first plurality of perforations 100. The coolant fluid is then directed by the refrigerant introduction plate 170 to a plurality of coolant channels 180 defined between the second plurality of tubes 132, wherein the plurality of coolant channels 180 define the second set of coolant channels 52 and have a shape and / or size determined at least in part by the placement, size, and / or shape of the second plurality of tubes 132. The coolant fluid is then directed along the plurality of coolant channels 180 and directed out of the coolant outlet 46.

[0084] Reference again Fig.10 ,exist Figures 8 to 10 In the illustrated embodiment, the refrigerant path 74 directs the refrigerant fluid through the heat exchanger 10. Specifically, the refrigerant path 74 directs the refrigerant fluid through the refrigerant inlet 36 and into the refrigerant inlet flow chamber 172, where the refrigerant fluid is directed into the inlet 160 of the second plurality of tubes 132. The refrigerant fluid then travels through the second plurality of tubes 132 and the second plurality of perforations 102. The refrigerant fluid is then directed by the coolant introduction plate 150 to a plurality of refrigerant channels 190 defined between the first plurality of tubes 130, wherein the plurality of refrigerant channels 190 define a second set of refrigerant channels 190 and have a shape and / or size determined at least in part by the placement, size, and / or shape of the first plurality of tubes 130. The refrigerant fluid is then directed along the plurality of refrigerant channels 190 and directed out of the refrigerant outlet 48.

[0085] like Fig.10 As shown, the coolant path 72 can be in a counter-flow configuration relative to the refrigerant path 74. This counter-flow allows heat transfer to occur between the coolant fluid and the refrigerant fluid as the coolant fluid travels through the first plurality of tubes 130, and the refrigerant fluid travels through the plurality of refrigerant channels 190 as the coolant fluid travels through the plurality of coolant channels 180 and the refrigerant fluid travels through the second plurality of tubes 132. In some embodiments, the coolant flow can be reversed so that the coolant fluid flows through the coolant outlet 46, through the plurality of coolant channels 180 and the first plurality of perforations 100, into the first plurality of tubes 130, and out of the coolant inlet 34. This alternative coolant path allows for a parallel flow configuration of the heat exchanger 10.

[0086] The use of the currently disclosed apparatus can provide a variety of advantages. For example, by utilizing the first cooling block 32, the second cooling block 44, and the baffle plate 56, the heat exchanger 10 allows for the use of a compact heat exchanger 10 in the vehicle 12. Specifically, due to the high surface area to volume ratio of the spiral icosahedron heat exchanger 10 relative to conventional heat exchangers, the use of spiral icosahedron structures (such as the first spiral icosahedron structure 38 and the second spiral icosahedron structure 50) allows for efficient heat transfer. In addition, the use of the first plurality of tubes 130 with the coolant introduction plate 150 and the use of the second plurality of tubes 132 with the refrigerant introduction plate 170 provides a compact heat exchanger 10 that can effectively allow heat transfer in the compact heat exchanger 10 relative to conventional heat exchangers.

[0087] It will be understood that changes and modifications may be made to the foregoing constructions without departing from the concepts of the present disclosure, and it will be further understood that such concepts are intended to be encompassed by the appended claims unless the claims expressly state otherwise by their language.

[0088] According to the present invention, a heat exchanger is provided, which comprises: a shell; a first cooling block defined in the shell, the first cooling block comprising a coolant inlet, a refrigerant inlet opposite to the coolant inlet, and a first spiral icosahedron structure defining a first group of coolant channels and a first group of refrigerant channels; a second cooling block defined in the shell, the second cooling block comprising a coolant outlet, a refrigerant outlet opposite to the coolant outlet, and a second spiral icosahedron structure defining a second group of coolant channels and a second group of refrigerant channels; and a perforated baffle plate inserted between the first cooling block and the second cooling block, wherein the first group of coolant channels are fluidly connected to the second group of coolant channels via the perforations in the baffle plate, and wherein the first group of refrigerant channels are fluidly connected to the second group of refrigerant channels via the perforations in the baffle plate.

[0089] According to one embodiment, the coolant inlet further comprises a coolant introduction channel directing the fluid flow into the first group of coolant channels, and wherein the refrigerant inlet further comprises a refrigerant introduction channel directing the fluid flow into the first group of refrigerant channels.

[0090] According to one embodiment, the coolant outlet further comprises a coolant removal channel directing the fluid flow out of the second set of coolant channels, and wherein the refrigerant outlet further comprises a refrigerant removal channel directing the fluid flow out of the second set of refrigerant channels.

[0091] According to one embodiment, at least one of the coolant introduction channel and the refrigerant introduction channel is defined by a first spiral icosahedron structure, and wherein at least one of the coolant removal channel and the refrigerant removal channel is defined by a second spiral icosahedron structure.

[0092] According to one embodiment, the housing, the first helical icosahedron structure, the second helical icosahedron structure, and the baffle plate are integrally coupled.

[0093] According to one embodiment, the first spiral tetrahedron structure defines a first conical recess near the coolant inlet and a second conical recess near the refrigerant inlet, wherein the second conical recess extends toward the first conical recess.

[0094] According to one embodiment, the second spiral tetrahedron structure defines a third conical recess near the coolant outlet and a fourth conical recess near the refrigerant outlet, wherein the fourth conical recess extends toward the third conical recess.

[0095] According to one embodiment, the coolant inlet and the coolant outlet are arranged on a front panel of the housing, and wherein the refrigerant inlet and the refrigerant outlet are arranged on a rear panel of the housing.

[0096] According to one embodiment, the coolant fluid is directed along a coolant path and the refrigerant fluid is directed along a refrigerant path, the refrigerant path being in a counter-flow configuration with respect to the coolant path.

[0097] According to the present invention, a heat exchanger is provided, which comprises: a shell; a first cooling block defined in the shell, the first cooling block comprising a coolant inlet and a refrigerant outlet opposite to the coolant inlet; a second cooling block defined in the shell, the second cooling block comprising a coolant outlet and a refrigerant inlet opposite to the coolant outlet; a first group of cooling channels and a first group of refrigerant channels defined in at least one of the first cooling block and the second cooling block; a second group of cooling channels and a second group of refrigerant channels defined in at least one of the first cooling block and the second cooling block; and a perforated baffle plate inserted between the first cooling block and the second cooling block, wherein the first group of coolant channels are fluidly connected to the second group of coolant channels via the perforations in the baffle plate, and wherein the first group of refrigerant channels are fluidly connected to the second group of refrigerant channels via the perforations in the baffle plate.

[0098] According to one embodiment, the helical icosahedron structure defines at least one of a first group of coolant channels, a second group of coolant channels, a first group of refrigerant channels, and a second group of refrigerant channels.

[0099] According to one embodiment, a first plurality of tubes are disposed in a first cooling block and a second plurality of tubes are disposed in a second cooling block, and wherein the first plurality of tubes define at least one of a first group of coolant channels and a second group of refrigerant channels, and wherein the second plurality of tubes define at least one of a second group of coolant channels and a first group of refrigerant channels.

[0100] According to one embodiment, a first set of coolant channels extends through a first plurality of tubes and a second set of coolant channels is defined by a space between each tube of the first plurality of tubes, and wherein the first set of coolant channels extends through a second plurality of tubes and the second set of coolant channels is defined by a space between each tube of the second plurality of tubes.

[0101] According to one embodiment, the present invention is also characterized by a coolant path that directs the coolant fluid through the first cooling block, across the baffle plate, and through the second cooling block; and a refrigerant path that directs the refrigerant fluid through the first cooling block, across the baffle plate, and through the second cooling block, wherein the refrigerant path directs the refrigerant fluid in a countercurrent manner relative to the coolant fluid in the coolant path.

[0102] According to one embodiment, the coolant inlet and the coolant outlet are arranged on the same side of the heat exchanger, and wherein the refrigerant inlet and the refrigerant outlet are arranged on the same side of the heat exchanger.

[0103] According to the present invention, a heat exchanger is provided, which comprises: a shell; a first cooling block defined in the shell, the first cooling block comprising a coolant inlet and a refrigerant outlet opposite to the coolant inlet; a second cooling block defined in the shell, the second cooling block comprising a coolant outlet and a refrigerant inlet opposite to the coolant outlet; a perforated baffle plate inserted between the first cooling block and the second cooling block, the perforated baffle plate defining a plurality of perforations on opposite ends of the baffle plate; a first plurality of tubes arranged in the first cooling block, the first plurality of tubes guiding the coolant fluid from the coolant inlet to the plurality of perforations; and a second plurality of tubes arranged in the second cooling block, the second plurality of tubes guiding the refrigerant fluid from the refrigerant inlet to the plurality of perforations.

[0104] According to one embodiment, the first plurality of tubes defines at least one of a first set of coolant channels and a second set of refrigerant channels, and wherein the second plurality of tubes defines at least one of the second set of coolant channels and the first set of refrigerant channels.

[0105] According to one embodiment, a first set of coolant channels extends through a first plurality of tubes and a second set of coolant channels is defined by a space between each tube of the first plurality of tubes, and wherein the first set of coolant channels extends through a second plurality of tubes and the second set of coolant channels is defined by a space between each tube of the second plurality of tubes.

[0106] According to one embodiment, the present invention is also characterized by: a coolant introduction plate arranged in the first cooling block, which is oriented obliquely and extends from the front panel of the shell to the rear panel of the shell; and a refrigerant introduction plate arranged in the second cooling block, which is oriented obliquely and extends from the rear panel and toward the front panel.

[0107] According to one embodiment, a first plurality of tubes are coupled to a coolant introduction plate, and wherein the first plurality of tubes each include an inlet, each inlet being flush with the coolant introduction plate, and wherein a second plurality of tubes are coupled to a refrigerant introduction plate, and wherein the second plurality of tubes each include an inlet, each inlet being flush with the refrigerant introduction plate.

Claims

1. A heat exchanger, comprising: case; a first cooling block defined within the housing, the first cooling block including a coolant inlet and a refrigerant outlet opposite the coolant inlet; a second cooling block defined within the housing, the second cooling block including a coolant outlet and a refrigerant inlet opposite the coolant outlet; a first set of cooling channels and a first set of refrigerant channels defined in at least one of the first cooling block and the second cooling block; a second set of cooling channels and a second set of refrigerant channels defined in at least one of the first cooling block and the second cooling block; as well as A baffle plate is interposed between the first cooling block and the second cooling block, wherein the first group of coolant channels are in fluid communication with the second group of coolant channels via perforations in the baffle plate, and wherein the first group of refrigerant channels are in fluid communication with the second group of refrigerant channels via perforations in the baffle plate.

2. The heat exchanger of claim 1, wherein a spiral icosahedron structure defines at least one of the first group of coolant channels, the second group of coolant channels, the first group of refrigerant channels, and the second group of refrigerant channels.

3. The heat exchanger of claim 1, further comprising a first spiral icosahedron structure disposed in the first cooling block and a second spiral icosahedron structure disposed in the second cooling block, wherein the first spiral icosahedron structure defines the first group of coolant channels, and the second spiral icosahedron structure defines the second group of coolant channels. 4 . The heat exchanger of claim 3 , wherein the housing, the first spiral icosahedron structure, the second spiral icosahedron structure, and the baffle plate are integrally coupled.

5. The heat exchanger of claim 3, wherein the coolant inlet further comprises a coolant introduction passage that directs fluid flow into the first group of coolant passages, and wherein the refrigerant inlet further comprises a refrigerant introduction passage that directs fluid flow into the first group of refrigerant passages.

6. The heat exchanger of claim 5, wherein the coolant outlet further comprises a coolant removal passage that directs fluid flow out of the second set of coolant passages, and the refrigerant outlet further comprises a refrigerant removal passage that directs fluid flow out of the second set of refrigerant passages.

7. The heat exchanger of claim 6, wherein at least one of the coolant introduction channel and the refrigerant introduction channel is defined by the first spiral icosahedron structure, and wherein at least one of the coolant removal channel and the refrigerant removal channel is defined by the second spiral icosahedron structure.

8. The heat exchanger of claim 3, wherein the first spiral tetrahedron structure defines a first conical recess proximate the coolant inlet and a second conical recess proximate the refrigerant inlet, wherein the second conical recess extends toward the first conical recess.

9. The heat exchanger of claim 8, wherein the second spiral tetrahedron structure defines a third conical recess proximate the coolant outlet and a fourth conical recess proximate the refrigerant outlet, wherein the fourth conical recess extends toward the third conical recess.

10. The heat exchanger of claim 1, wherein the first plurality of tubes are disposed in the first cooling block and the second plurality of tubes are disposed in the second cooling block, and wherein the first plurality of tubes define at least one of the first group of coolant channels and the second group of refrigerant channels, and wherein the second plurality of tubes define at least one of the second group of coolant channels and the first group of refrigerant channels.

11. The heat exchanger of claim 10, wherein the first set of refrigerant channels extends through the first plurality of tubes and the second set of refrigerant channels is defined by the space between each tube in the first plurality of tubes, and wherein the first set of refrigerant channels extends through the second plurality of tubes and the second set of refrigerant channels is defined by the space between each tube in the second plurality of tubes.

12. The heat exchanger according to claim 11, further comprising: a coolant introduction plate disposed in the first cooling block, the coolant introduction plate being obliquely oriented and extending from the front panel of the housing to the rear panel of the housing; as well as A refrigerant introduction plate is provided in the second cooling block, the refrigerant introduction plate being obliquely oriented and extending from the rear panel toward the front panel.

13. The heat exchanger of claim 12, wherein the first plurality of tubes are coupled to the coolant introduction plate, and wherein the first plurality of tubes each include an inlet, each inlet being flush with the coolant introduction plate, and wherein the second plurality of tubes are coupled to the refrigerant introduction plate, and wherein the second plurality of tubes each include an inlet, each inlet being flush with the refrigerant introduction plate.

14. The heat exchanger of any one of claims 1 to 13, wherein the coolant inlet and the coolant outlet are arranged on the same side of the heat exchanger, and wherein the refrigerant inlet and the refrigerant outlet are arranged on the same side of the heat exchanger.

15. A heat exchanger as described in any one of claims 1 to 13, further comprising a coolant path that directs a coolant fluid through the first cooling block, across the baffle plate, and through the second cooling block; and a refrigerant path that directs a refrigerant fluid through the first cooling block, across the baffle plate, and through the second cooling block.

16. The heat exchanger of claim 15, wherein the refrigerant path directs refrigerant fluid in a counter-flow manner relative to the coolant fluid in the coolant path.

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