HEAT EXCHANGER WITH REGIONAL FLOW DISTRIBUTION FOR EVEN COOLING OF BATTERY CELLS

Abstract

Heat exchanger plate (12) with a heat transfer surface (28, 30) comprising a first heat transfer zone (32) and a second heat transfer zone (34): (a) a first subgroup of fluid flow channels (40) provided in the first heat transfer zone (32), wherein the first subgroup of fluid flow channels (40) has a first flow capacity, (b) a second subgroup of fluid flow channels (40) provided in the second heat transfer zone (34), wherein the second subgroup of fluid flow channels (40) has a second flow capacity which is less than the first flow capacity; (c) at least one fluid inlet channel (52); (d) at least one fluid outlet channel (56); (e) a fluid inlet opening (50) in flow connection with the at least one fluid inlet channel (52); and (f) a fluid outlet opening (54) in flow connection with the at least one fluid outlet channel (56); wherein each of the flow channels (40) has a first end which is connected to and in flow communication with one of the at least one fluid inlet channels (52); and wherein each of the fluid flow channels (40) has a second end which is connected to and in flow communication with one of the at least one fluid outlet channels (56), wherein the at least one fluid inlet channel (52) includes a first fluid inlet channel and a second fluid inlet channel, both of which are in flow communication with the fluid inlet opening (50), wherein the first end of each of the fluid inlet channels of the first subgroup is in flow communication only with the first fluid inlet channel; and wherein the first end of each of the fluid flow channels (40) of the second subgroup is in flow communication only with the second fluid inlet channel, wherein the first and second fluid inlet channels are separated by an inlet channel rib (64), the inlet channel rib having a closing end which is spaced apart from an edge of the fluid inlet opening (50) such that a fluid distribution space is provided between the edge of the fluid inlet opening (50) and the closing end of the inlet channel rib, and / or, wherein the at least one fluid outlet channel (56) includes a first fluid outlet channel and a second fluid outlet channel, both of which are in flow communication with the fluid outlet opening (54), wherein the second end of each of the fluid flow channels (40) of the first subgroup is in flow communication only with the first fluid outlet channel; and wherein the second end of each of the fluid flow channels (40) of the second subgroup is in flow communication only with the second fluid outlet channel, wherein the first and second fluid outlet channels are separated by an outlet channel rib (64), wherein the outlet channel rib (64) has a closing end which is spaced apart from an edge of the fluid outlet opening (54) such that a fluid distribution space (66) is provided between the edge of the fluid outlet opening (54) and the closing end of the outlet channel rib (64).

Description

CROSS-REFERENCE TO A RELATED REGISTRATION

[0001] This application claims the priority and benefits of provisional patent application No. 62 / 170765, filed in the USA on June 4, 2015, the contents of which are incorporated herein by reference. AREA OF INVENTION

[0002] The invention relates to a heat exchanger for thermal management of batteries, wherein the heat exchanger comprises a plurality of discrete heat exchanger plates, and in particular to such heat exchangers which have structural features for improving the uniformity of cooling over the surfaces of the battery cells and for reducing a pressure drop of the coolant flowing through the heat exchanger. BACKGROUND

[0003] Rechargeable batteries, such as those made up of many lithium-ion cells, can be used in many applications, including electric vehicles (EVs) and electric hybrid vehicles (HEVs). During charging and discharging, these batteries can generate large amounts of heat that must be dissipated.

[0004] In advanced thermal management systems for batteries, individual battery cells are arranged between liquid-cooled heat exchanger plates that have flow channels for coolant. The amount of heat removed from the cell is related to the flow rate of the coolant through the plate. However, as the flow rate increases, so does the pressure drop, thus limiting the coolant flow rate and the cooling capacity of the plate.

[0005] Additionally, most heat exchanger plates are designed to ensure a uniform coolant distribution across the plate surfaces. However, the heat generated by a lithium-ion battery is not evenly distributed across its surface. For example, hot spots can develop at and near the battery terminals, especially during rapid charging, as the terminals of lithium-ion battery cells tend to generate more heat than the rest of the cell. Furthermore, hot spots can develop in the center of the battery cell during discharge under driving cycle conditions.Therefore, cooling such a battery with plates designed for uniform coolant distribution can result in uneven cooling of the battery cells, creating "hot spots" that can negatively impact battery performance and lifespan. Thus, dissipating excess heat, whether from areas near the battery terminals or from other parts of the battery cell, would improve battery performance and lifespan.

[0006] From CN 104051818 A, a metal plate arrangement is known that defines a plurality of cooling channels. The metal plate arrangement includes an inlet section for introducing a coolant into the multiple cooling channels and an outlet section from which the coolant exits the multiple cooling channels. US 2013 / 0209856 A1 deals with a cooling system for an automotive battery. One or more fins are in thermal contact with one or more battery cells. A fluid is caused to flow from a high-pressure side through a cavity in each fin to a low-pressure side.

[0007] There is a need for improved heat exchanger design for rechargeable batteries with improved manufacturing capabilities, providing lower pressure drop and / or more uniform cooling. DEMOLITION

[0008] In one aspect, a heat exchanger plate with a heat transfer surface comprising a first heat transfer zone and a second heat transfer zone is provided. The heat exchanger plate includes: (a) a first subset of fluid flow channels provided in the first heat transfer zone, wherein the first subset of fluid flow channels has a first flow capacity; (b) a second subset of fluid flow channels provided in the second heat transfer zone, wherein the second subset of fluid flow channels has a second flow capacity that is less than the first flow capacity; (c) at least one fluid inlet channel; (d) at least one fluid outlet channel; (e) a fluid inlet opening in flow communication with the at least one fluid inlet channel; and (f) a fluid outlet opening in flow communication with the at least one fluid outlet channel.wherein each of the fluid flow channels has a first end which is connected to and in flow communication with one of the at least one fluid inlet channels; and wherein each of the fluid flow channels has a second end which is connected to and in flow communication with one of the at least one fluid outlet channels.

[0009] In another aspect, a heat exchanger plate for cooling a battery cell with a plurality of terminals is provided. The heat exchanger plate comprises: at least one first head section located at a first end of the plate, wherein the at least one head section includes a fluid inlet head section and / or a fluid outlet head section; a second head section located at a second end of the plate; a plurality of flow channels extending from the first end to the second end of the plate; wherein the at least one first head section and / or the second head section have a first height that is greater than a second height of the flow channels, and is essentially the same as the distance between terminals of adjacent batteries when separated by one of the heat exchanger plates.

[0010] In another aspect, a heat exchanger is provided which comprises a plurality of heat exchanger plates, as described here. The heat exchanger plates are arranged in a spaced and parallel relationship to one another, with the fluid inlet and outlet openings in flow connection with respective fluid inlet and outlet manifolds.

[0011] In another aspect, a heat exchanger is provided which comprises a plurality of repeating units. Each repeating unit comprises a first battery cell, a second battery cell adjacent to the first battery cell, and a heat exchanger plate, as described herein, adjacent to the second battery cell, wherein a space is provided between the terminals of the first battery cell and the terminals of the second battery cell in each repeating unit, and wherein the space is at least partially filled with an elongated strip of filler material. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The invention will now be described only by way of example with reference to the attached drawing, in which: Fig. 1 is a perspective view showing a pair of battery cells and a pair of heat exchanger plates of a battery module according to an exemplary embodiment, Fig. 2 a cross-section along the section line 2-2' of the Fig. 1 is; Fig. 3 to 6 simplified top views of different heat exchanger plates with parallel arrangements of fluid flow channels are shown; Fig. 7 is a top view of a heat exchanger plate according to a further embodiment; Fig. Figure 8 shows a detailed view of an area that shows the outlet opening of the heat exchanger plate. Fig. 1 or Fig. surrounds 7; Fig. 9 to 11 partial views of the heat exchanger plates are shown, representing different types of flow obstructions; Fig. 12A and Fig. 12B shows a heat exchanger plate according to another embodiment; Fig. 13 and Fig. 14 show a heat exchanger plate according to another embodiment which has a 1:1 configuration and has plates with enlarged head sections for battery terminal cooling; Fig. Figure 15 shows an end view of a heat exchanger plate which has an enlarged head section for battery terminal cooling, according to another embodiment; Fig. 16 shows a heat exchanger plate according to another embodiment; Fig. 17 shows a heat exchanger plate according to another embodiment; Fig. 18 to 20 simplified top views of various heat exchanger plates, which have parallel arrangements of fluid flow channels and the inlet and outlet connections at opposite ends; and Fig. 21 and Fig. 22 show a heat exchanger according to another embodiment, which has plates with enlarged head parts for battery terminal cooling and filler strips to fill the spaces between adjacent battery cells. DETAILED DESCRIPTION

[0013] Fig. Figure 1 represents a heat exchanger 10 according to a first embodiment. The heat exchanger 10 comprises a plurality of heat exchanger plates 12. Although only two plates 12 of the heat exchanger 10 are shown in Fig. As shown in Figure 1, it is understood that the heat exchanger can contain 10 additional plates 12.

[0014] The heat exchanger plates 12 are arranged in a spaced, parallel relationship to each other, the distance between adjacent heat exchanger plates 12 being sufficient to accommodate a pair of battery cells 14, each battery cell 14 having a surface in close thermal contact with one of the heat transfer surfaces of an adjacent plate 12 and an opposite surface that is directed towards the other battery cell 14. Fig. Figure 1 represents a pair of battery cells 14 that are sandwiched between a pair of adjacent heat exchanger plates 12. However, it should be noted that the heat exchanger 10 can include additional battery cells 14 that can be sandwiched between additional pairs of spaced-apart plates 12. The combination of the battery cells 14 and the heat exchanger 10 is here referred to as a battery module 1, in which the plurality of plates 12 encompassed by the heat exchanger 10 are arranged in an alternating arrangement with pairs of battery cells 14, as shown in Figure 1. Fig. 1 and in the partial cross-section of the Fig. 2 are shown arranged.

[0015] It should be noted that battery module 1 of the Fig. 1 and Fig. 2 will comprise a plurality of repeating units, each comprising two battery cells 40 and a heat exchanger plate 12, and is sometimes referred to here as a “2:1 configuration”. In accordance with this 2:1 configuration, one surface of each battery cell 14 is in thermal contact with a heat exchanger plate 12, while the opposite surface faces an adjacent battery cell 14. The two adjacent battery cells 14 of each repeating unit in the 2:1 configuration may be separated from each other by a spacer layer 130, as shown in Fig. 2 shown. The number of repeating units in the battery module is variable. Although the embodiments described here are based on battery modules in a 2:1 configuration, it should be noted that the heat exchanger plates described in this application can be used in heat exchangers and battery modules with different configurations. For example, the heat exchanger plates and heat exchangers described here can be used in battery modules where the repeating units comprise a battery cell 14 and a heat exchanger plate 15, which is also referred to here as a “1:1 configuration”. The embodiments described below Fig. 13 and Fig. Figure 14 represents an embodiment in which the repeating unit has a 1:1 configuration.

[0016] Each battery cell 14 has a pair of flat, opposing surfaces for contact with the heat exchanger surfaces of the plates 12 and a pair of terminals 16, 18 to provide an electrical connection with a busbar (not shown), the busbar being similarly connected to the terminals 16, 18 of the other cells 14 in the battery module 1. As shown in Fig. As shown in Figure 1, the terminals 16, 18 will typically have a thickness that is less than that of the other parts of the battery cell 14.

[0017] During charging or discharging of the battery module, heat is generated by the battery cells 14. As described above, the heat generated by the battery cells 14 can be unevenly distributed across the surfaces of the battery cells 14, creating a temperature gradient along the outer surfaces of the battery cells 14 and thus generating "hot spots" in one or more areas of the battery cells 14. For example, since the terminals of lithium-ion battery cells tend to generate more heat than the rest of the battery cells, each of the battery cells 14 of the battery module 1 can experience a temperature gradient, with the temperature of the battery cell 14 being highest at or near the terminals 16, 18 (the upper region of the battery cell 14, as shown in Figure 1). Fig. 1 shown, in or near zone 20) will be highest, since a higher electrical current density exists in this area, especially during fast charging of battery module 1. During battery discharge under driving cycle conditions, each of the battery cells 14 can also experience a temperature gradient, with the temperature of battery cell 14 being highest near the middle region of battery cell 14 (the middle region of battery cell 14, as shown in Fig. 1 shown, will be in or near zone 24),

[0018] In the embodiment described below, the heat exchanger plates 12 of the battery module 1 are provided with multiple cooling zones, the zone(s) of highest cooling capacity being located closest to the terminals 16, 18 of the battery cells 14 in order to prevent the formation of hot spots in the area of ​​the terminals 16, 18. It should be noted that the battery module can include heat exchanger plates 12 in which the zone(s) of highest cooling capacity are located closest to the central parts of the battery cells 14, either in addition to or instead of the heat exchanger plates 12 described below.

[0019] In Fig. Figure 1 shows the battery cell 14 having four thermal zones, each with a different temperature range and cooling requirements. These four thermal zones are: a first thermal zone 20 near terminals 16, 18, which has the highest temperature range and the greatest cooling requirements; a second thermal zone 22 adjacent to zone 20, which has a lower temperature range and lower cooling requirements than zone 20; a third thermal zone 24 adjacent to zone 22, which has a lower temperature range and lower cooling requirements than zone 22; and a fourth thermal zone 26, which has the lowest temperature range and the least cooling requirements. The divisions between thermal zones 20, 22, 24, and 26 in Figure 1 are shown. Fig. 1 are shown by dashed lines. Given that the battery cell has a temperature gradient across its surface (i.e., in Fig. (1 from the bottom to the top) it should be noted that the division of cell 14 into four heat areas is somewhat arbitrary and that the number of heat areas may differ from the one shown.

[0020] Each heat exchanger plate 12 has a pair of opposing heat exchanger surfaces 28, 30, which will be in close thermal contact with one of the flat surfaces of the battery cell 14, with heat being transferred from the cell 14 to the coolant via the heat transfer surfaces 28, 30. To maximize heat transfer, the heat transfer surfaces 28, 30 of the plates 12 have approximately the same size, shape, and area as the flat surfaces of the battery cell 14 to be cooled.

[0021] Each heat transfer surface 28, 30 of the heat exchanger plate 12 is shown as divided into four heat transfer zones, labelled 32, 34, 36 and 38. Fig. The heat transfer zones are designated 1, with the division between adjacent heat transfer zones shown by dashed lines. Furthermore, each of the heat transfer zones of the heat exchanger plate 12 corresponds approximately to one of the heat regions of the battery cell 14 in terms of location, size, shape, and area. In this respect, the first heat transfer zone 32 of the heat exchanger plate 12 is configured to be in contact with the first heat region 20 of the cell 14; the second heat transfer zone 34 of the heat exchanger plate 12 is configured to be in contact with the second heat region 22 of the cell 14; the third heat transfer zone 36 of the heat exchanger plate 12 is configured to be in contact with the third heat region 24 of the cell 14; and the fourth heat transfer zone 38 of the heat exchanger plate 12 is configured to be in contact with the fourth heat region 26 of the cell 14.

[0022] While the present embodiment relates to a battery cell 14 with four thermal zones and a heat exchanger plate 12 with four heat transfer zones, it should be noted that this is an exemplary setup and the number of thermal zones and heat transfer zones may be either fewer or more than those shown in the figures. For example, the invention includes embodiments in which the battery cell 14 has a first thermal zone 20 near the terminals 16, 18 and a second thermal zone 22 distal to the terminals 16, 18, while the heat exchanger plate 12 has a first heat transfer zone 32 for thermal contact with the first thermal zone 20 of the cell 14 and a second heat transfer zone 34 for contact with the second thermal zone 22.

[0023] As in Fig. As shown in Figure 1, the heat exchanger plate 12 comprises a plurality of fluid flow channels 14 to transport coolant over the surfaces 28, 30 of the heat exchanger plate 12. As shown in the cross-section of the Fig. As shown in Figure 2, the fluid flow channels 40 have a substantially constant height, with the thickness of the heat exchanger plate 12 being defined by the height of the fluid flow channels 40. The fluid flow channels 40 can have flat top and bottom surfaces, as shown, for improved surface contact with a battery cell 14, although in some embodiments the top and bottom surfaces of the channels 40 may be rounded. The fluid flow channels 40 of the heat exchanger plate 12 are shown to be relatively narrow and do not require internal support structures in the form of nipples, ribs, or turbulators.

[0024] Each heat transfer zone of the heat exchanger plate 12 is provided with a subgroup of fluid flow channels 40, each subgroup also comprising a plurality of fluid flow channels 40. In this respect, the first heat transfer zone 32 includes a first subgroup 42 of fluid flow channels 40, the second heat transfer zone 34 includes a second subgroup 44 of fluid flow channels 40, the third heat transfer zone 36 includes a third subgroup 46 of fluid flow channels 40, and the fourth heat transfer zone 38 includes a fourth subgroup 48 of fluid flow channels 40.

[0025] Each of the first to fourth subgroups of fluid flow channels 40 has a specific fluid flow capacity, which is the sum of the fluid flow capacities of the individual fluid flow channels 40 that form a subgroup. Therefore, the fluid flow capacity of each subgroup of fluid flow channels 40 is determined partly by the number of fluid flow channels 40 that form the subgroup and also by the fluid flow capacities of the individual fluid flow channels 40 that form the subgroup. As discussed further below, the fluid flow capacity of each individual fluid flow channel 40 is determined at least partly by its cross-sectional area and by the presence or absence of any local flow obstructions in the fluid flow channel 40.

[0026] In the illustrated embodiment, for example, the first subgroup 42 comprises two fluid flow channels 40; the second subgroup 44 comprises four fluid flow channels 40; the third subgroup 46 comprises five fluid flow channels 40; and the fourth subgroup 48 comprises six fluid flow channels 40. It should be noted, however, that the number of channels in each subgroup can vary from that shown in the figures and that the number of fluid flow channels 40 is only one parameter that influences the fluid flow capacity of the subgroups. Despite the increase in the number of fluid flow channels 40 from the first to the fourth subgroup, the fluid flow capacity of the subgroups decreases with increasing distance from the terminals 16, 18 of the battery cells 14. This is discussed further below.

[0027] The heat exchanger plate 12 also comprises a fluid inlet opening 50 through which coolant enters the heat exchanger plate 12 and which is in flow communication with at least one fluid inlet channel 52, each of which is in the form of an elongated head section connected to a subset of fluid flow channels 40. The heat exchanger plate 12 also comprises a fluid outlet opening 54 through which coolant is discharged from the heat exchanger plate 12 and which is in flow communication with at least one fluid outlet channel 56, each of which is in the form of an elongated head section connected to a subset of fluid flow channels 40.Although not shown in the drawing, the fluid inlet openings 50 of the heat exchanger plates 12, which form a heat exchanger 10, are connected to a coolant inlet manifold and the fluid outlet openings 54 of the heat exchanger plates 12 are connected to a coolant outlet manifold, the inlet and outlet manifolds being in flow communication with a coolant circuit system which may include a pump and a fan-cooled radiator or other heat exchangers for removing heat from the coolant.

[0028] In the illustrated embodiment, the heat exchanger plate 12 comprises four fluid inlet channels 52, all of which are in flow communication with a single fluid inlet opening 50, and four fluid outlet channels 56, all of which are in flow communication with a common fluid outlet opening 54. The fluid inlet and outlet channels 52, 54 can have flat top and bottom surfaces, as shown in Fig. 2, for improved surface contact with the surfaces of the battery cell 14, although the top and bottom surfaces of channels 40 may be rounded in some embodiments. The fluid inlet and outlet channels 52, 56 are shown as relatively narrow and do not require internal support structures in the form of nubs, ribs, or turbulators.

[0029] Each of the fluid flow channels 40 has a first end 58, through which it is connected to one of the fluid inlet channels 52, and a second end 60, through which it is connected to one of the fluid outlet channels 56. Therefore, coolant taken in through the fluid inlet opening 50 flows via the at least one fluid inlet channel 52 to the fluid flow channel 40, flows from the first ends 58 to the second ends 60 of the fluid flow channels 40 to at least one fluid outlet channel 56, and then flows through the at least one fluid outlet channel 56 to the fluid outlet opening 54.

[0030] The heat exchanger plate 12 can be manufactured from a pair of identical sheets 62, which are embossed with a pattern of raised and recessed areas that form the fluid flow channels 40 and the fluid inlet and outlet channels 52, 56 when the sheets 62 are brought into direct contact. The circumferential edges and the recessed areas of the sheets 62 are tightly joined together, for example by welding or brazing, to form flat areas 64 that separate the fluid flow channels and the inlet and outlet channels 52, 56 and extend along the outer circumferential edges of the heat exchanger plates 12. In the following description, the flat areas 64 between the fluid flow channels 40 are sometimes referred to as "ribs".

[0031] No coolant flows through the flat areas 64. The widths of the flat areas 64 can be minimized to maximize the area of ​​the heat exchanger plate 12 occupied by the fluid flow channels 40 and the fluid inlet and outlet channels 52, 56. Although all fluid flow channels 40 are also in Fig. Where two are shown with the same width, it should be noted that they may have different widths along at least part of their lengths.

[0032] The heat exchanger 10 incorporates a number of improvements to minimize the pressure drop of a coolant flowing through the heat exchanger plates 12. Reducing the pressure drop in the heat exchanger plates 12 allows the coolant to flow through them at a higher velocity, thereby increasing the amount of heat removed from the battery cells 14. The inventors found that a heat exchanger plate 12, as described in Fig. The heat exchanger plate designed as shown in section 1 has a pressure drop of 2.3 kPa at a flow rate of 60 ml / min. In contrast, a heat exchanger plate according to the prior art, which has a convoluted flow path, has a pressure drop of 16 kPa at a flow rate of 60 ml / min.

[0033] In the present embodiment, the pressure drop is minimized by the fact that the fluid flow channels 40 are predominantly straight and parallel to each other. In this configuration, the first end 58 of each fluid flow channel 40 is connected to one of the fluid inlet channels 52 at an angle of approximately 90 degrees, and the second end 60 of each fluid flow channel 40 is connected to one of the fluid outlet channels 56 at an angle of approximately 90 degrees.

[0034] With the possible exception of the fourth subgroup 48, the fluid flow channels 40 in each of the subgroups 42, 44, and 46 are essentially straight and parallel to each other and are also essentially parallel to the fluid flow channels 40 of the other subgroups 42, 44, and 46. In the fourth subgroup 48, some of the fluid flow channels 40 (i.e., the three lowest fluid flow channels 40 in Fig. 1) Deviates somewhat from a straight, parallel arrangement to provide coolant distribution over a region of the fourth heat transfer zone 38 located between the fluid inlet channels 52, fluid outlet channels 56, and fluid flow channels 50. However, even in the fourth subgroup 48, the fluid flow channels 40 have slight deviations from a straight, parallel configuration and experience much smaller changes in direction than a flow channel in a conventional plate, which may experience some 90 or 180-degree changes in direction as it flows through the plate. For example, the three lowest fluid flow channels 40 in the fourth subgroup 48 experience changes in direction that are less than 90 degrees in total.

[0035] Furthermore, the parallel fluid flow channels 40 are generally directed along a first axis of the heat exchanger plate 12, which is parallel to the horizontal direction in Fig. 1, while the fluid inlet and fluid outlet channels 52, 56 are generally directed along a second axis of the heat exchanger plate 12 in at least a part of their lengths, the second axis being parallel to the vertical direction in Fig. 1 is and is essentially perpendicular to the first axis. In this respect, each pair of fluid inlet and fluid outlet channels 52, 56 is shown as straight and parallel to the second axis, at least in regions where they are connected to the ends 58, 60 of the fluid flow channels 40. Furthermore, in the illustrated embodiment, the fluid inlet and fluid outlet channels 52, 56 are located close to the circumferential edges of the heat exchanger plate 12 (i.e., the vertical edges in Fig. 1) at least in areas where they are connected to the ends 58, 60 of the fluid flow channels, in order to maximize the areas of the heat transfer surfaces 28, 30 through which coolant circulates. Thus, the fluid inlet and fluid outlet channels 52, 56 and the fluid flow channels describe numerous, generally U-shaped channels which together provide substantially complete coverage of the heat transfer surfaces 28, 30, thereby achieving a much lower pressure drop than with convoluted channels of a heat exchanger plate according to the prior art.

[0036] It should be noted that widening the fluid flow channels 40 and / or the fluid inlet and outlet channels 52, 56 is another way to reduce pressure drop, although this may require nipples and / or other structural features to provide support or stiffening for the widened channels. The present embodiment allows channels 40, 52, and 56 to have a relatively narrow width, thus avoiding the need for structural supports within the channels while maintaining a low pressure drop.

[0037] Numerous changes to the number and configurations of channels 40, 52, and 56 are possible while maintaining a low pressure drop. Some of these exemplary changes are described below with reference to the Fig. Figures 3 to 6 are described, which are simplified top views of the heat exchanger plates 12, in which channels 40, 52 and 56 are shown as simple lines.

[0038] Fig. Figure 3 represents an embodiment of a heat exchanger plate 12 having only a single fluid inlet channel 52, a single fluid outlet channel 56, and a plurality of fluid flow channels 40 extending between the fluid inlet and fluid outlet channels 52 and 56, thus representing the simplest arrangement of channels 40, 52, and 56 in accordance with the invention. Although not shown in Figure 3, the following applies: Fig. As shown in Figure 3, different heat transfer zones and / or a staggered flow distribution can be created by changing the widths of channels 40, 52 and 56 and / or by providing local flow obstructions, as described below.

[0039] Fig. Figure 4 represents an embodiment of a heat exchanger plate 12 in which two fluid inlet channels 52 are provided, wherein a first fluid inlet channel 52 is in flow connection with the first ends 58 of a first subgroup of fluid flow channels 40, and a second fluid inlet channel 52 is in flow connection with the first ends 58 of a second subgroup 44 of flow channels 40. In this embodiment, only a single fluid outlet channel 56 is provided, which is in flow connection with the second ends 60 of all fluid flow channels 40. This arrangement creates a first and second heat transfer zone 32, 34, which are shown as separated by dashed lines.

[0040] Fig. Figure 5 represents an embodiment of a heat exchanger plate 12 in which only a single fluid inlet channel 52 is provided, which is in flow connection with the first ends 58 of all flow channels 40. In this embodiment, two fluid outlet channels 56 are provided, wherein a first fluid outlet channel 56 is in flow connection with the second ends 60 of a first subgroup 42 of fluid flow channels 40, and wherein a second fluid outlet channel 52 is in flow connection with the second ends 60 of a second subgroup 44 of fluid flow channels 40. This arrangement also creates a first and second heat transfer zone 32, 34, which are shown separated by a dashed line. The embodiments according to Fig. 4 and Fig. Figure 5 shows that the number of fluid inlet channels 52 does not necessarily have to be the same as the number of fluid outlet channels 56.

[0041] Fig. Figure 6 shows an embodiment of a heat exchanger plate 12 in which two fluid inlet channels 52 and two fluid outlet channels 56 are provided, wherein the first fluid inlet channel 52 and the first fluid outlet channel 56 are in flow communication with a first subgroup 42 of fluid flow channels 40, and a second fluid inlet channel 52 and a second fluid outlet channel 56 are in flow communication with a second subgroup 44 of fluid flow channels 40. This arrangement also generates first and second heat transfer zones 32, 34, which are shown as divided by a dashed line.

[0042] Fig. Figure 7 shows a heat exchanger plate 12, which bears a high degree of similarity to the heat exchanger plate 12 of the Fig. 1 has and is similarly provided with four heat transfer zones 32, 34, 36, 38. The second, third and fourth heat transfer zones 34, 36, 38 of the heat exchanger plate 12 of the Fig. 7 have essentially the same structure as the corresponding zones of the Fig. 1. The uppermost heat transfer zone 32 of the heat exchanger plate 12 according to Fig. However, 7 is shown extending upwards into the area of ​​the terminals 16, 18 of the battery cells 14 and includes additional fluid flow channels 40 (also referred to as 4c and 4d in Fig. 7) through which coolant circulates in this area. Therefore, the heat exchanger plate 12 is located after Fig. 7 adapted to remove heat directly from the terminals 16, 18 in addition to removing heat from the first to fourth thermal regions 20, 22, 24, 26 of the battery cell 14. Direct cooling of the terminals 16, 18 is also beneficial because the terminals 16, 18 are connected to aluminum and copper strips (not shown) of high thermal conductivity, which can remove heat from the center of the battery cell 14. Therefore, the extension of the heat transfer zone 32 into the terminal region can remove some of the heat conducted from the center of the cell 14 through the conductive strips.

[0043] As in Fig. As shown in Figure 1, the battery terminals 16, 18 are thinner than those of the rest of the battery cell. Therefore, to ensure close contact between the heat exchanger plate 12 and the terminals 16, 18, the thickness of the heat transfer zone 32 in the terminal area can be greater than the thickness of the rest of the heat exchanger plate 12, as described below in connection with the exemplary embodiment of the Fig. It is written as 13 to 15.

[0044] To further reduce pressure drop, the heat exchanger plates 12 described here also include flow adaptation features that create differences in flow capacity between different subgroups of fluid flow channels 40, thus providing multiple heat transfer zones with different cooling capacities. Some of these heat exchanger plates 12 described here include flow adaptation features that create differences in the fluid transport capacities of the fluid flow channels 40 in one or more subgroups, thus providing the heat exchanger plate 12 with a graduated cooling capacity across its surface. Some of these embodiments are now described below with reference to the Fig. 1, Fig. 7 and Fig. 8 described.

[0045] First, they illustrate Fig. 1 and Fig. 7, that the flow capacities of the various subgroups of fluid flow channels 40 can be adjusted by making changes in the cross-sectional areas of the fluid flow channels 40, the fluid inlet channels 52 and / or the fluid outlet channels 56. Since the height of the channels 40, 52 and 56 is determined by the thickness of the heat exchanger plate 12, a change in the cross-sectional areas of the channels 40, 52 and 56 can be achieved by changing their widths.

[0046] For example, close in Fig. 1 and Fig. 7 The heat exchanger plates 12 have four fluid inlet channels 52, each feeding a different heat transfer zone 32, 34, 36, 38. The width of the fluid inlet channel 52 that supplies coolant to the first heat transfer zone 32, which is located at or near the area of ​​the ports 16, 18, is greater than that of the fluid inlet channels 52 that feed the other heat transfer zones, while the width of the fluid inlet channel 52 that supplies the fourth heat transfer zone, which is furthest from the ports 16, 18, is narrower than that of the other fluid inlet channels 52. The widths of the fluid inlet channels 52, which supply the second and third heat transfer zone 34, 36, are between those of the first and fourth heat transfer zone 32, 38, wherein the fluid inlet channel 52, which supplies coolant to the second heat transfer zone 34, is wider than the fluid inlet channel 52, which supplies coolant to the third heat transfer zone 36.It can be seen that changing the width of the fluid inlet channels in this way leads to the pressure drop that increases from the widest fluid inlet channel 52 to the narrowest fluid inlet channels 52, and therefore the flow velocity of the coolant through the first heat transfer zone 32 will be greatest, while the coolant flow velocity through the fourth heat transfer zone 38 will be lowest.

[0047] In the same way, as in the Fig. 1 and Fig. As shown in Figure 7, the widths of the fluid outlet channels 56 can be varied in a similar manner and can result in a similar effect on the pressure drop and the coolant flow velocities in the four heat transfer zones 32, 34, 36, 38. In these embodiments, the width of the fluid outlet channel 56 that carries coolant away from the first heat transfer zone 32 is the largest, while that of the fluid outlet channel 56 that carries coolant away from the fourth heat transfer zone 38 is the smallest.

[0048] Similarly, the widths of the fluid flow channels 40 in the respective heat transfer zones can differ from one another to produce a similar effect with respect to the pressure drop and coolant flow velocities in the four heat transfer zones 32, 34, 36, 38. For example, the widths of the fluid flow channels 40 in the first subgroup 42, which is located in the first heat transfer zone 32, can be larger than the widths of the fluid flow channels 40 in the other subgroups, with the widths of the fluid flow channels 40 in the fourth subgroup 48 being the smallest.

[0049] It should be noted that the changes described above regarding the width of channels 40, 52, and 56 can be used alone or in combination. For example, the heat exchanger plate 12 can be provided with fluid inlet channels 52 of different widths, while the fluid outlet channels 56 and fluid flow channels 40 remain at a constant width; the fluid outlet channels 56 can be of different widths, while the fluid inlet channels 52 and fluid outlet channels 40 are kept at a constant width; or the fluid flow channels 40 of the different zones can be of different widths, while the width of the fluid inlet and fluid outlet channels 52 and 56 is kept constant.

[0050] In addition to or instead of adjusting the width of channels 40, 52, 56, the heat exchanger plates 12 of the Fig. 1 and Fig. 7 an additional feature for providing heat transfer zones 32, 34, 36, 38 with different cooling capacities. This additional feature is now described below with reference to Fig. 8 described, which is an enlarged representation of the area that contains the fluid outlet opening 54 of the heat exchanger plate 12 of the Fig. 1 or Fig. 7 surrounds, shows.

[0051] Fig. Figure 8 shows the four fluid outlet channels 56 for transporting fluid from the heat transfer zones 32, 34, 36 and 38. For clarity, the four fluid outlet channels 56, which are in Fig. 8 are shown, identified as 56(32), 56(34), 56(36) and 56(38) to connect them to the respective heat transfer zone.

[0052] It can be made of Fig. 8 can be seen that the four fluid outlet channels 56 are separated from each other by three ribs 64, which are in Fig. 8 are designated 64a, 64b, and 64c. As shown, the tips or tails of the ribs 64a, 64b, and 64c are spaced from the edge of the fluid outlet opening 54 such that a fluid distribution space 66 is created between the edge of the fluid outlet opening 54 and the tails of the ribs 64a, 64b, and 64c. The coolant from each of the four fluid outlet channels 56 will enter this fluid distribution space 66. In the configuration according to Fig. 8 However, there will not be an equal distribution of the coolant between the four fluid outlet channels 56.

[0053] As in Fig. As shown in Figure 8, the distance 68 between ribs 64b and 64c and the outlet opening 54 is less than the distance 70 between ribs 64a and fluid outlet opening 54. In other words, the tip or end of rib 64a is farther from the edge of the fluid outlet opening 54 than the tips or ends of ribs 64b and 64c. Thus, the "frontal area" of the fluid outlet channels 56(32) and 56(34), separated by ribs 64a, is larger than the frontal area of ​​the fluid outlet channels 56(36) and 56(38). As a result of this increased frontal area, the coolant in the fluid outlet channels 56(32) and 56(34) will experience a lower pressure drop as it flows into the distribution area 66, thereby creating differences in flow capacity between the fluid outlet channels 56. The Fig. The feature generated in 8 can be incorporated into the heat exchanger plate 12 as an independent feature or can be used in combination with the changes regarding the width of the channels 40, 52 and / or 56, as described above. It should also be noted that the distance between the edge of the fluid outlet opening 54 and the fins 64b and 64c need not necessarily be the same, but rather different, in order to generate differences in flow capacity between the fluid channels 56(36) and 56(38). It should be noted that a similar distribution area 66 between the fluid inlet opening 50 and the ends of the fins 64, which separate the four fluid inlet channels 52 from one another, can be provided to generate the effects mentioned above, and this arrangement is shown in Fig. 7 shown.

[0054] It should be noted that the flow control features, as described above, generate variations in the flow capacities of the different heat transfer zones 32, 34, 36, 38. Alternatively or additionally to providing changes in the flow capacities between the different heat transfer zones, the heat exchanger plates 12 can be provided with flow control features to generate changes in the fluid-carrying capacities of the fluid flow channels 40 in one or more heat transfer zones. This provides a graduated cooling capacity in one or more heat transfer zones. This aspect of the invention will now be described with reference to the Fig. 1 and Fig. 7 described.

[0055] To simplify the explanation, the fluid flow channels 14 of the second to fourth heat transfer zones 34, 36, 38 are shown in the Fig. Numbers 1 to 7 are designated as 2a - 2d, 3a - 3e and 4a - 4f. In Fig. 1 the fluid flow channels 40 of the first heat transfer zone 32 are designated as 1a - 1b and in Fig. These 7 channels are designated as 1a - 1d.

[0056] It can be seen that the widths of the fluid flow channels 40 in the second to fourth heat transfer zones 34, 36, 38 increase from bottom to top with respect to the heat transfer zone. Thus, the width of the fluid flow channels 40 in each of these heat transfer zones increases towards the upper region of the heat exchanger plate 12, which will be in contact with the hottest region of the battery cell 14, and the cooling capacity in these heat transfer zones increases in the same way towards the upper part of the heat exchanger plate 12.

[0057] It can also be from the Fig. 1 and Fig. Figure 7 shows that the widths of the fluid flow channels 40 in the second to fourth heat transfer zones 34, 36, 38 are similar to each other. More precisely, the fluid flow channels 40 designated 2a, 3a, and 4a can be of the same or similar width; the fluid flow channels 40 designated 2b, 3b, and 4b can be of the same or similar width, and so on. Thus, while there is a graduated cooling capacity in these heat transfer zones 34, 36, 38, the widths of the fluid flow channels 40 in one heat transfer zone can be the same or similar to the widths of the fluid flow channels 40 in one or more of the other heat transfer zones. Therefore, in the embodiments of Fig. 1 and Fig. 7 the differences in flow capacity and cooling capacity in the various heat transfer zones 32, 34, 36, 38 are largely determined by the widths of the fluid inlet and fluid outlet channels 52, 56, while the differences in flow capacity and cooling capacity in the second to fourth heat transfer zone 34, 36, 38 are determined by the differences in the width of the individual fluid flow channels 40 in these heat transfer zones 34, 36, 38.

[0058] In the first heat transfer zone 32 in each of the Fig. 1 and Fig. 7. There is a lesser difference in the widths of the fluid flow channels 40. In this zone 32, which has the greatest cooling capacity, the widths of the fluid flow channels 40 will be at the larger end of the width range. Therefore, the fluid flow channels 40 that are in Fig. 1 are designated 1a to 1b, and the fluid flow channels 40, which are in Fig. The fluid flow channels 40, designated 1a to 1d, are of the same or similar width as the fluid flow channels 40 designated 2c to 2d, 3d to 3e and 4e to 4f in the second to fourth heat transfer zones 34, 36, 38. It should be understood, however, that the widths of the fluid flow channels 40 in the first heat transfer zone 32 may have the same or similar gradations in width as shown in the second to fourth heat transfer zones 34, 36, 38.

[0059] The flow control characteristics mentioned above with reference to the Fig. 1, Fig. 7 and Fig. As discussed in Section 8, the provision of different flow and cooling capacities between the various heat transfer zones and within each heat transfer zone allows for considerable flexibility in the design of heat exchanger plates 12 for cooling battery cells 14. However, it should be understood that the flow control features discussed above must be formed during the stamping of the individual sheets 62 that constitute the heat exchanger plates 12, and that they are typically applied to all heat exchanger plates 12 in the battery 10. This can be limiting for some applications, for example, where not all heat exchanger plates 12 in the battery 10 will have exactly the same coolant flow distribution.

[0060] Therefore, in some embodiments, the heat exchanger plates 12 can alternatively or additionally be provided with flow-controlling features suitable for providing different flow and cooling capacities between and / or within the various heat transfer zones. These flow-controlling features are added to the heat exchanger plates 12 either during or after the stamping of the sheets 62 and / or during or after the assembly of the sheets 62 to form the heat exchanger plates 12. These flow-controlling features will take the form of local flow restrictions in at least some of the fluid flow channels 40 of one or more subgroups 42, 44, 46, 48 and / or in the fluid inlet and fluid outlet channels 52, 56. These features are now described with reference to the Fig. 9 to 11 described below.

[0061] Fig. Figure 9 is a partial cross-sectional view through a heat exchanger plate 12, showing three flow channels which can be the fluid flow channels 40, fluid inlet channels 52, or fluid outlet channels 56. Each of the three in Fig. The nine depicted flow channels exhibit different forms of local deformation. The flow channel on the left side of the Fig. 9 is provided with corrugations 72 in both the upper and lower walls of the channel. These corrugations 72 can be provided only in the upper wall or the lower wall of the channel, as in the left channel of the Fig. 10, depending on the desired degree of flow restriction. The beads will locally reduce the cross-sectional area of ​​the channel, creating a constriction point that restricts the flow through the channel, thus providing an effect similar to reducing the channel's width. The dimensions of the beads 72 can be varied to vary the degree of flow restriction.

[0062] The middle flow channel of the Fig. 9 and the middle flow channel of the Fig. 10 is provided with a lateral deformation 74 in which one side of the channel is indented, thereby locally reducing the cross-sectional area of ​​the channel and creating a constriction point that throttles the flow through the channel. These lateral deformations 74 can be provided on both sides of the channel or on its top or bottom and can be of different dimensions, depending on the desired degree of flow throttling.

[0063] The right flow channel of the Fig. 9 and the middle flow channel of the Fig. Both components 11 are provided with a deformation 76 in the upper part of the channel, extending across its entire width. This deformation 76 is similar to a rib extending transversely across the channel. These ribs 76 can be provided in the upper and lower walls of the channel and can be of variable size, depending on the desired degree of flow restriction.

[0064] It should be understood that the local deformations have different dimensions and shapes in addition to those shown in the drawing. The local deformations can be formed by pushing or pressing the flow channel with tools, either before or after sheets 92 are assembled to form plates 12.

[0065] The Fig. 12A and Fig. 12B represent a heat exchanger plate 12 according to an embodiment similar to the heat exchanger plate 12 described in Fig. Figure 3 shows a single fluid inlet channel 52 and a single fluid outlet channel 56. According to this embodiment, the fluid inlet and outlet channels 52, 56 are significantly wider than those of the embodiments described above. To provide structural reinforcement, the fluid inlet and outlet channels 52, 56 are provided with flat-bottomed studs 78 in the upper and lower sheets 62 of the heat exchanger plate 12, these flat-bottomed studs 78 being formed during the stamping of the plates. The flat bottoms of the flat-bottomed studs 78 in the upper and lower sheets 72 are sealed together by welding or brazing in the same manner as the other flat areas 64 that form the heat exchanger plate 12.

[0066] The heat exchanger plate of the Fig. 12A and Fig. 12B comprises a plurality of fluid flow channels 40 branching off from the fluid inlet and fluid outlet channels 52, 56. Although these fluid flow channels are slightly curved, they can be considered to be essentially straight and parallel to each other, thus providing the heat exchanger plate 12 with a low pressure drop.

[0067] The heat exchanger plate 12 of the Fig. 12A and Fig. 12B can be provided with two or more different heat transfer zones across their flat surfaces 28, 30, or with a single heat transfer zone with a graduated cooling capacity from the lower to the upper part of the heat exchanger plate 12. These configurations can be achieved by varying the widths of the fluid flow channels 40, as described above with reference to the Fig. 1 and Fig. 7 described, and / or the fluid flow channels are provided with local deformations, as described in section 7. Fig. described in sections 9 to 11. In the specific embodiment according to the Fig. 12A and Fig. In Figure 12B, the fluid flow channels 40 all have essentially the same width, and local deformations are used to throttle the fluid flow through at least some of the fluid flow channels 40. This can best be seen in Fig. Figure 12B shows that the fluid flow channels 40 near the lower part of the heat exchanger plate 12 exhibit lateral deformations 74 near their second ends 60. As in Fig. As shown in Figure 12A, similar lateral deformations 74 can be provided near the first ends 58 of the fluid flow channels 14. Multiple heat transfer zones or graduated cooling capacities can be generated by either providing these local deformations 74 in the flow channels 40 near the lower part of the heat exchanger plate 12 and not restricting the flow capacity through the fluid flow channels 40 near the upper part of the heat exchanger plate 12, or, as shown, reducing the dimensions of the local deformations 74 from the lower to the upper part of the heat exchanger plate 12, thus obtaining a heat exchanger plate 12 with increased flow and cooling capacity from the lower to the upper part of the plate.

[0068] As mentioned above with reference to Fig. As discussed in section 7, the areas of the heat exchanger plates can be extended into the area of ​​the terminals 16, 18 of the battery cell 14. A description of a heat exchanger 82 according to a further embodiment, which is made from a plurality of heat exchanger plates 80 as described in the following, is given below. Fig. Figures 13 to 15 show that the heat exchanger plates 80 are spaced apart and arranged parallel to each other, with the distance between adjacent heat exchanger plates 80 being sufficient to accommodate a battery cell 14 in close thermal contact with the heat transfer surfaces of the adjacent heat exchanger plates 80. Fig. 14 and Fig. 15 represent a single battery cell 14 that is accommodated between a pair of adjacent heat exchanger plates 80; however, it should be noted that the heat exchanger 82 can include additional battery cells 14 that are accommodated between additional pairs of spaced-apart heat exchanger plates 80 to form a battery module similar to the battery module 1 described above, which comprises a plurality of heat exchanger plates 80 and a plurality of battery cells 14 in an alternating arrangement.

[0069] The heat exchanger plate 80 has a two-pass configuration, including an inlet head section 84 and an outlet head section 86 located at a first end 90 of the plate 80, and a deflecting head section 88 at an opposite, second end 92 of the plate 80. The inlet and outlet head sections 84 and 86 each extend over half the width of the heat exchanger plate 80 and are provided with respective inlet and outlet openings 94 and 96 through which a liquid coolant is received by and discharged from the heat exchanger plate 80. The deflecting head section 88 extends over the entire width of the heat exchanger plate 80.

[0070] In the longitudinal direction between the first and second ends 90, 92 of the heat exchanger plate, a plurality of inlet flow channels 98 extend from the inlet head section 84 to the deflection head section 88, and a plurality of outlet flow channels 100 extend from the deflection head section 88 to the outlet head section 86. The inlet and outlet flow channels 98, 100 are analogous to the fluid flow channels 40 in the embodiments described above and can similarly have flat upper and lower surfaces for improved contact with the flat surfaces 28, 30 of the battery cells 14.Furthermore, the construction of the heat exchanger plate 80 can be similar to that of the heat exchanger plate 12 described above, which is constructed from a pair of identically stamped sheets 102 that are in closer proximity to each other, with the flat areas between the flow channels 98, 100 and the circumferential edges of the sheets 102 being tightly connected to each other, e.g. by welding or brazing.

[0071] In the embodiment according to the Fig. 13 and Fig. The first end 90 of the heat exchanger plate 80 is located at the end of the battery cell 14 that is distal, i.e., farther away from the terminals 16, 18. This arrangement may be desirable in some applications because it places the fluid connections at the inlet and outlet 94, 96 as far away as possible from the area of ​​the terminals 16, 18, where there is open access to the system voltage.

[0072] In the Fig. 13 and Fig. 14 The length of the heat exchanger plate is sufficient so that the deflecting head part 88 lies in a space between the terminals 16, 18 of the battery cells 14, which are separated by the heat exchanger plate 80 in which the deflecting head part 88 is arranged. As in Fig. As shown in Figure 14, the deflector head section 88 is extended in height relative to the height of the inlet and outlet flow channels 98, 100, the height of the deflector head section 88 being essentially the same as the distance between the terminals 16, 18 of adjacent battery cells 14, such that the upper and lower surfaces 104, 106 of the deflector head section 88 can be in thermal contact with surfaces of the terminals 16 and 18. Furthermore, the upper and lower surfaces 104, 106 of the deflector head section can be flattened to improve contact with the flat surfaces of the terminals 16, 18.

[0073] Although the examples of implementation according to the Fig. 13 and Fig. 14 The deflecting head part 88, which is extended in height and lies between the terminals 16, 18 of the adjacent battery cells 14, need not be the case in all embodiments. For example, Fig. Figure 15 shows an end view of an alternative embodiment of a heat exchanger plate 80, in which the inlet and outlet head sections 84, 86 are extended in height and are arranged between the terminals 16, 18 of adjacent battery cells. As in the embodiment of the Fig. 13 and Fig. 14 have the inlet and outlet head part 84, 86 of the embodiment according to Fig. 15 a height that is essentially the same as the distance between the terminals 16, 18 of adjacent battery cells, such that the upper and lower surfaces of the head parts 84, 86 can be in thermal contact with the surfaces of the terminals 16, 18. Furthermore, the upper and lower surfaces of the head parts 84, 86 can be flattened to improve contact with the flat surfaces of the terminals 16, 18. Also, in this embodiment, the inlet and outlet openings 94, 96 can extend horizontally rather than longitudinally, so that they project from the sides of the heat exchanger plates 80, thereby avoiding interference with the terminal rail (not shown) or other electrical components.

[0074] It is also possible to adapt the present embodiment to situations in which the terminals 16 and 18 are located at opposite ends of the battery cells 14. In such an embodiment, the deflecting head section 88 and the inlet and outlet head sections 84, 86 can be extended in height and located between the terminals 16, 18 of adjacent battery cells 14, as shown in the Fig. 14 and Fig. 15 is shown in each case. Alternatively, the heat exchanger plate can comprise a single-pass heat exchanger plate, in which the inlet head 84 is located at the first end 90 and the outlet head 86 is located at the second end 92, with both the inlet and outlet heads 84, 86 extending over the entire width of the heat exchanger plate 80. In such an arrangement, the inlet and outlet heads 84, 86 can be extended in height and be located between the terminals 16, 18 of adjacent battery cells 14 such that each is positioned in the Fig. 14 and Fig. 15 is shown.

[0075] Although the longitudinally extending, straight, parallel inlet and outlet channels 98, 100 the heat exchanger plate 80 of the Fig. 13 to 15, which have a low pressure drop, do not provide zoned cooling between the first end 90 and the second end 92 of the heat exchanger plate 80. Exemplary embodiments of a single-pass and a double-pass heat exchanger plate, similar to those described above with reference to the Fig. The procedures described in sections 13 to 15, which provide for zoned cooling, are now being discussed with reference to the Fig. 16 and Fig. 17 described. Fig. 16 and Fig. 17 share a number of elements with the exemplary embodiments that are in the Fig. 13 to 15 are described, and identical elements are given the same reference symbols.

[0076] Fig. Figure 16 represents a heat exchanger plate 80 in a single-pass arrangement, which has an inlet head section 84 at the first end 90 of the heat exchanger plate 80 and an outlet head section 86 at the opposite second end 92. The inlet and outlet head sections 84, 86 both extend over the entire width of the heat exchanger plate 80 and are provided with respective inlet and outlet openings 94, 96, through which a liquid coolant is introduced and discharged from the heat exchanger plate 80.

[0077] The plate comprises a plurality of flow channels 108, each extending from the inlet head section 84 to the outlet head section 86. Each flow channel 180 includes a spiral section 110, which is provided over a portion of the plate 80 corresponding to a cooling zone. Four such cooling zones 112, 114, 116, and 118 are arranged in Fig. 16 defined, each corresponding to the area occupied by one of the spiral parts 110. Although Fig. Figure 16 shows four spiral parts 110 with a similar shape and a specific quadrilateral spiral shape. It should be noted that the spiral parts 110 can have different shapes and dimensions. It should also be noted that the inlet head part and / or the outlet head part 84, 86 can be extended in height and can be arranged in the area between the terminals 16 and / or 18 of the battery cell, as shown in the embodiments described above. Fig. Figures 13 to 15 are shown.

[0078] Fig. Figure 17 represents a heat exchanger plate 80 having a two-pass arrangement and an inlet head section 84 and an outlet head section 86, which are arranged at the first end 90 of the heat exchanger plate 80 and include a deflecting head section 88 at an opposite second end 92 of the heat exchanger plate 80. The inlet and outlet head sections 84, 86 each extend over half the width of the heat exchanger plate 80 and are provided with respective inlet and outlet openings 94, 96, through which a liquid coolant is introduced into and discharged from the heat exchanger plate 80. The deflecting head section 88 extends over the entire width of the heat exchanger plate 80. Either the deflecting head section 88 or the inlet head section and the outlet head section 84, 86 can be extended in height and be located between the terminals 16 and 18 of adjacent battery cells, as shown in the Fig. Shown 13 to 15.

[0079] Between the first and second ends 90, 92 of the heat exchanger plate 80, a plurality of inlet flow channels 98 extend from the inlet head section 84 to the deflection head section, and a plurality of outlet flow channels 100 extend from the deflection head section 88 to the outlet head section 86. Each of the inlet and outlet flow channels 98, 100 comprises a helical section 110, which is provided over a portion of the heat exchanger plate 80 corresponding to a cooling zone. Four such cooling zones 112, 114, 116, and 118 are arranged in Fig. 17 defined, where each corresponds to the area occupied by one of the spiral parts 110. Although Fig. Figure 16 shows four spiral parts 110 with the same shape and with a specific square spiral shape; it should be noted that the spiral parts 110 can have different shapes and dimensions.

[0080] The Fig. The heat exchanger plates 12 shown in Figures 1 to 8 generally have U-shaped flow paths, with the fluid inlet opening 50 and the fluid outlet opening 54 located at the same end of the heat exchanger plate 12. Fig. Figures 18 to 20 represent heat exchanger plates according to other embodiments in which the fluid inlet and outlet openings 50, 54 are arranged at opposite ends of the heat exchanger plate. The heat exchanger plates of the Fig. 18 to 20 share a number of common elements with the heat exchanger plates 12, which are located in the Fig. Figures 1 to 8 are shown. These common elements are labelled below and in the figures with the same reference symbols, and unless otherwise indicated, the above descriptions of these elements apply with reference to the figures. Fig. 1 to 8 also on the Fig. 18 to 20.

[0081] Fig. Figure 18 represents a heat exchanger plate 120 in which the fluid inlet opening 50 and the fluid outlet opening 54 are arranged at opposite ends of the heat exchanger plate 120 and at diagonally opposite corners. The heat exchanger plate 120 of the Fig. The heat exchanger plate 120 is divided into five heat transfer zones 32, 34, 36, 38, 39, each of which comprises two or more parallel fluid flow channels 40 connected to a fluid inlet channel 52 and a fluid outlet channel 56, and oriented at approximately 90 degrees to the fluid inlet and outlet channels 52, 56. The direction of fluid flow through all channels 40 is the same and is parallel to the ends of the heat exchanger plate 120. In this embodiment, the fluid inlet and outlet channels 52, 56 extend parallel to the sides of the heat exchanger plate 120, and the fluid flow channels 40 extend parallel to the ends of the heat exchanger plate 120.

[0082] In the embodiment according to Fig. 18 The fluid flow channels 40 of the two uppermost heat transfer zones 32, 34 have their first ends 58 in flow communication with the respective inlet channels 52a, 52b, wherein the fluid inlet channel 52b is in Fig. Figure 18 shows a branch of the fluid inlet channel 52a. The second ends 60 of these same fluid flow channels 40 are in flow connection with a common fluid outlet channel 56a.

[0083] In the embodiment according to Fig. 18 are the fluid flow channels 40 of the middle heat transfer zone 36 in flow connection with a fluid inlet channel 52c and a fluid outlet channel 56b.

[0084] The fluid flow channels 40 of the lowest heat transfer zones 38, 39 of the embodiment according to Fig. 18 have second ends 60 which are in flow communication with respective fluid outlet channels 56c and 56d, wherein fluid outlet channel 56c is a branch of fluid outlet channel 56d. The first ends 58 of this same fluid flow channel 40 are in flow communication with a common fluid inlet channel 52d.

[0085] Fig. Figure 19 represents a heat exchanger plate 130 in which the fluid inlet opening 50 and the fluid outlet opening 54 are directly opposite each other and located at opposite ends of the plate 130. The heat exchanger plate 130 is divided into four heat transfer zones 32, 34, 36, and 38, each comprising three or more parallel fluid flow channels 40 connected to a fluid inlet channel 52 and a fluid outlet channel 56, and oriented at approximately 90 degrees to the fluid inlet channel 52 and the fluid outlet channel 56. The direction of the fluid flow through the fluid flow channels 40 is indicated by the arrows in Fig. 19 and is the same for all fluid flow channels 40. In this embodiment, the fluid flow channels 40 extend parallel to the sides of the heat exchanger plate 130, and the fluid inlet and fluid outlet channels 52, 56 extend parallel to the ends of the heat exchanger plate 130. The fluid inlet channels 52 each comprise an elongated head section that is connected to the fluid inlet opening 50 via an inlet transition channel 132. Similarly, the fluid outlet channels 56 each comprise an elongated head section that is connected to the fluid outlet opening 54 via an outlet transition channel 134.

[0086] In the embodiment according to Fig. 19 The fluid flow channels 40 of the two outermost heat transfer zones 32, 38 have their first ends 58 in flow communication with the respective fluid inlet channels 52a, 52d. The second ends 60 of these same fluid flow channels 40 are in flow communication with the respective fluid outlet channels 56a, 56d. The fluid flow channels 40 of the two innermost heat transfer zones 34, 36 are in flow communication with the respective fluid inlet channels 52b, 52c and with the respective fluid outlet channels 56b, 56c.

[0087] Fig. Figure 20 represents a heat exchanger plate 140 in which the fluid inlet opening 50 and the fluid outlet opening 54 are arranged directly opposite each other and are located at opposite ends of the heat exchanger plate 140. The heat exchanger plate 140 is divided into four heat transfer zones 32, 34, 36 and 38, with an outermost pair of heat transfer zones 32, 38 and an innermost pair of heat transfer zones 34, 36 being provided. The outermost pair of heat transfer zones 32, 38 each comprises two parallel fluid flow channels 40, which are connected to a respective fluid inlet channel 52a, 52d and to a respective fluid outlet channel 56a, 56d and are oriented at approximately 90 degrees to the fluid inlet and fluid outlet channels 52a, 52d, 56a, 56d and parallel to the sides of the heat exchanger plate 140, the direction of the fluid flow through the fluid flow channels 40 of the heat transfer zones 32, 38 being indicated by arrows in Fig. 20 is displayed.

[0088] The innermost two heat transfer zones 34, 36 comprise fluid flow channels 40, which are U-shaped, each having a first end 58 in flow communication with a respective fluid inlet channel 52b, 52c and a second end 60 in flow communication with a respective fluid outlet channel 56b, 56c. In the embodiment according to Fig. 20 The fluid inlet and fluid outlet channels 52b, 52c, 56b, 56c are arranged centrally in the heat exchanger plate 140, wherein the fluid inlet and fluid outlet channels 52b, 56b are essentially collinear, as are the fluid inlet and fluid outlet channels 52c, 56c.

[0089] Each fluid flow channel 40 in each of the innermost two heat transfer zones 34, 36 comprises a first leg 40a and a second leg 40b. In heat transfer zone 34, the first and second legs 40a, 40b are connected to each other via a deflection head section 142. Similarly, in heat transfer zone 36, the first and second legs 40a, 40b are connected to each other via a deflection head section 144. Both legs 40a, 40b of each fluid flow channel 40 are arranged parallel to the ends of the plate 140.

[0090] Additional examples of implementation are now given with reference to the Fig. 21 and Fig. 22 described. The exemplary embodiment of the Fig. 13 and Fig. 14 has repeating units in the same manner, each comprising a heat exchanger plate 80 and a battery cell 14, wherein each plate 80 has a deflector head part 88 with a height approximately equal to the distance between the terminals 16, 18 of adjacent battery cells 14, such that the terminals 16, 18 of each battery cell 14 are arranged between and in thermal contact with the deflector head parts 88 of adjacent plates 80. Therefore, in a 1:1 configuration of the Fig. 13 and Fig. 14 the connections 16, 18 on both sides are supported by the deflection head parts 88.

[0091] The Fig. 21 and Fig. 22 represent part of a battery module 1, which contains a plurality of battery cells 14 and a plurality of heat exchanger plates 80 similar to those according to the Fig. 13 and Fig. 14. However, the embodiment differs according to the Fig. 21 to 22 of the embodiment according to the Fig. 13 to 14 in that the repeater unit of battery module 1 in the Fig. Figures 21 to 22 comprise two battery cells 14 and a heat exchanger plate 80, and are sometimes referred to here as the “2:1 configuration”. In accordance with this 2:1 configuration, one surface of each battery cell 14 is in thermal contact with a heat exchanger plate 80, while the opposite surface faces the adjacent battery cell 14. The two adjacent battery cells 14 of each repeating unit in the 2:1 configuration can be separated from each other by a spacer layer 130. The spacer layer 130 can comprise substantially the same area as the battery cells 14 and can be made of a compliant, deformable material, such as a polymer foam, which deforms upon compression of the battery module 1.

[0092] As can be seen from the Fig. As can be seen in Figures 21 to 22, in the 2:1 configuration, the terminals 16, 18 of each battery cell 14 are in contact with the deflecting head part 88 of only one adjacent heat exchanger plate 80, and there is a gap 132 between the terminals 16, 18 of the two battery cells 14 in each repeating unit. To provide support for the terminals 16, 18, the gap 132 can be filled with an elongated strip of filler 134. In the embodiment according to Fig. 21 The filler strip 134 is a cylindrical rod and can be made of a compliant, deformable material, such as a polymer foam. For example, the filler strip 134 can comprise an open-cell polyurethane foam. Although the filler strip 134 according to Fig. It should be noted that the filler strip 134 is formed in the form of a cylindrical rod (21), but this is not essential. The filler strip 134 can have any desired cross-sectional shape, including rectangular, square, triangular (i.e., wedge-shaped), or any non-circular rounded shape, including oval, egg-shaped, etc. The cross-sectional shape and dimensions of the filler strip 134 are chosen such that the strip 134 fits into the space 132 and does not interfere with the terminal rail or other electrical components near the terminals 16, 18.

[0093] In the configuration after Fig. 21 The filler strips 134 are individually arranged in the spaces 132 between each adjacent pair of battery cells 14. To improve the manufacturing efficiency, the filler strips 134 can be connected to each other in a comb-like support structure 136, as shown in the Fig. Figure 22 shows that the filler strips 134 form the teeth of the comb and that an edge of each filler strip 134 is attached to a connecting part 138. The connecting part 138 of the support structure 136 is also arranged so that it does not interfere with the connecting rail or other electrical components.

[0094] Although the Fig. Figures 21 to 22 show the heat exchanger plates 80 as if they had essentially the same configuration as in the Fig. 13 to 14, it should be noted that the 2:1 configuration also includes heat exchanger plates 80 in accordance with the embodiment shown in the illustration. Fig.15 can be used in which the inlet and outlet head sections 84, 86 are extended in height and are located between the terminals 16, 18 of adjacent battery cells 14. In such an embodiment, each terminal 16 or 18 is supported on one side by the inlet or outlet head section 84 or 86 of an adjacent heat exchanger plate 80, while opposite sides of the terminals 16, 18 are supported by a filler strip 134, as described above.

[0095] Although the invention has been described in connection with certain embodiments, it is not limited thereto. The invention can, however, include all embodiments that fall within the scope of the following claims.

Claims

[1] Heat exchanger plate (12) with a heat transfer surface (28, 30) having a first heat transfer zone (32) and a second heat transfer zone (34), comprising: (a) a first subset of fluid flow channels (40) provided in the first heat transfer zone (32), the first subset of fluid flow channels (40) having a first flow capacity, (b) a second subset of fluid flow channels (40) provided in the second heat transfer zone (34), the second subset of fluid flow channels (40) having a second flow capacity less than the first flow capacity; (c) at least one fluid inlet channel (52); (d) at least one fluid outlet channel (56); (e) a fluid inlet opening (50) in flow communication with the at least one fluid inlet channel (52); and (f) a fluid outlet opening (54) in flow communication with the at least one fluid outlet channel (56); wherein each of the flow channels (40) has a first end connected to and in flow communication with one of the at least one fluid inlet channels (52); and wherein each of the fluid flow channels (40) has a second end connected and in flow communication with one of the at least one fluid outlet channels (56), wherein the at least one fluid inlet channel (52) includes a first fluid inlet channel and a second fluid inlet channel, both in flow communication with the fluid inlet opening (50), wherein the first end of each of the fluid inlet channels of the first subset is in flow communication only with the first fluid inlet channel; and wherein the first end of each of the fluid flow channels (40) of the second subgroup is in flow communication only with the second fluid inlet channel, wherein the first and second fluid inlet channels are separated by an inlet channel rib (64), the inlet channel rib having a terminal end spaced from an edge of the fluid inlet opening (50) such that a fluid distribution space is provided between the edge of the fluid inlet opening (50) and the terminal end of the inlet channel rib, and / or, wherein the at least one fluid outlet channel (56) includes a first fluid outlet channel and a second fluid outlet channel, both of which are in flow communication with the fluid outlet opening (54), wherein the second end of each of the fluid flow channels (40) of the first subgroup is in flow communication only with the first fluid outlet channel; and wherein the second end of each of the fluid flow channels (40) of the second subgroup is in flow communication only with the second fluid outlet channel, wherein the first and second fluid outlet channels are separated by an outlet channel rib (64), the outlet channel rib (64) having a terminal end spaced from an edge of the fluid outlet opening (54) such that a fluid distribution space (66) is provided between the edge of the fluid outlet opening (54) and the terminal end of the outlet channel rib (64). [2] The heat exchanger plate of claim 1, wherein the first end of each of the fluid flow channels is connected to one of the at least one fluid inlet channels at an angle of approximately 90 degrees; and wherein the second end of each of the fluid flow channels is connected to one of the at least one fluid outlet channels at an angle of approximately 90 degrees. [3] A heat exchanger plate according to claim 1 or 2, wherein each of the fluid flow channels of the first subset is substantially straight and parallel to each of the other fluid flow channels of the first subset, and wherein each of the fluid flow channels of the second subset is substantially straight and parallel to each of the other fluid flow channels of the second subset. [4] A heat exchanger plate according to any one of claims 1 to 3, wherein the first subset of fluid flow channels is substantially parallel to the second subset of fluid flow channels. [5] A heat exchanger plate according to any one of claims 1 to 4, wherein the first and second subsets of fluid flow channels (40) are directed generally along a first axis of the heat exchanger plate. [6] A heat exchanger plate according to claim 5, wherein each of the fluid inlet and fluid outlet channels (52, 56) is directed generally along a second axis of the heat exchanger plate along at least a portion of its length, the first axis being substantially perpendicular to the second axis. [7] A heat exchanger plate according to claim 6, wherein each of the fluid inlet and fluid outlet channels (52, 56) is substantially parallel to the second axis at least in regions where it connects to the ends of the fluid flow channels. [8] Heat exchanger plate according to one of claims 1 to 7, wherein each of the fluid inlet and fluid outlet channels (52, 56) is located near an edge of the heat exchanger plate (12) at least in regions where it is connected to the ends of the fluid flow channels (40). [9] Heat exchanger plate according to one of claims 1 to 8, wherein a difference between two different fluid transporting capacities is at least partially effected by the provision of local flow obstructions in at least some of the fluid flow channels (40) of the first subgroup and / or the second subgroup. [10] A heat exchanger plate according to claim 9, wherein each of the local flow obstructions comprises a deformation in the shape of one of the fluid flow channels, thereby locally reducing the cross-section. [11] A heat exchanger plate according to claim 9 or 10, wherein the fluid flow channels of the first and second subgroups have substantially the same width and height. [12] A heat exchanger plate according to any one of claims 1 to 8, wherein a difference between two different fluid transporting capacities is effected at least in part by providing at least some of the fluid flow channels (40) of the first sub-group with a greater width than at least some of the fluid flow channels (40) of the second sub-group. [13] Heat exchanger plate according to one of claims 1 to 12, wherein each of the fluid flow channels (40) of the first subgroup has substantially the same fluid transporting capacity; and / or each of the fluid flow channels (40) of the second subgroup has substantially the same fluid transporting capacity. [14] Heat exchanger plate according to one of claims 1 to 9, wherein a fluid transporting capacity of the fluid flow channels (40) in the first subgroup and / or the second subgroup is variable such that a graded cooling capacity is provided in the first heat transfer zone (32) and / or the second heat transfer zone (34). [15] A heat exchanger plate according to claim 14, wherein the variability of the fluid transporting capacities of the fluid flow channels in the first subgroup and / or the second subgroup is at least partly due to the provision of local flow obstructions in at least some of the fluid flow channels of the first subgroup and / or the second subgroup. [16] A heat exchanger plate according to claim 15, wherein each of the local flow obstacles comprises a deformation in the shape of one of the fluid flow channels (40) which locally reduces its cross-section. [17] Heat exchanger plate according to claim 14, wherein the variability of the fluid transporting capacities of the fluid flow channels (40) is provided at least in part by varying the widths of the fluid flow channels (40) of the first subgroup and / or the second subgroup. [18] Heat exchanger plate according to one of claims 1 to 17 with two heat transfer surfaces. [19] A heat exchanger plate according to any one of claims 1 to 18, wherein the plate includes a plurality of fluid inlet channels and wherein adjacent fluid inlet channels are separated by inlet channel ribs (64), each of the inlet channel ribs (64) having a terminal end spaced from an edge of the fluid inlet opening (50) such that a fluid distribution space is provided between the edge of the fluid inlet opening (50) and the terminal end of the ribs (64). [20] The heat exchanger plate of claim 19, wherein a first end of the inlet channel ribs (64) separating a first of the fluid inlet channels and a second of the fluid inlet channels is spaced from the edge of the fluid inlet opening (50) by a greater distance than a second of the inlet channel ribs separating the second fluid inlet channel from a third of the fluid inlet channels. [21] A heat exchanger plate according to any one of claims 1 to 18, wherein the plate encloses a plurality of said fluid outlet channels and wherein adjacent fluid outlet channels are separated by outlet channel ribs (64a, 64b, 64c), each of said outlet channel ribs (64a, 64b, 64c) having a terminal end spaced from an edge of said fluid outlet opening (54) such that a fluid distribution space is provided between the edge of said fluid outlet opening (54) and the terminal ends of said outlet channel ribs (64a, 64b, 64c). [22] The heat exchanger plate of claim 21, wherein a first of the outlet channel ribs (64a) separating a first of the fluid outlet channels and a second of the fluid outlet channels is spaced from the edge of the fluid outlet opening by a greater distance than a second of the outlet channel ribs (64b) separating the second fluid outlet channel from a third of the fluid outlet channels. [23] A heat exchanger comprising a plurality of heat exchanger plates according to any one of claims 1 to 22, wherein the heat exchanger plates (12) are arranged in a spaced parallel relationship to one another, the fluid inlet and fluid outlet openings (50, 54) being connected in flow communication with respective fluid inlet and fluid outlet manifolds. [24] Heat exchanger according to claim 23, wherein a distance between adjacent heat exchanger plates (12) is sufficient to accommodate two battery cells. [25] The heat exchanger of claim 24, wherein the battery cell has a plurality of terminals and a first thermal region proximate the terminals and a second thermal region distal to the terminals, and wherein the heat exchanger is adapted to receive the battery cell with the first thermal region of the battery cell in contact with the first heat transfer zone (32) of adjacent plates and with the second thermal region of the battery cell in contact with the second heat transfer zone (34) of the adjacent plates. [26] Heat exchanger plate (12) according to one of claims 1 to 22, wherein the heat exchanger plate is arranged for cooling a battery cell having a plurality of terminals, comprising: at least one first header located at a first end of the plate, the at least one header including a fluid inlet header and / or a fluid outlet header; a second headboard located at a second end of the board; wherein the flow channels (40) extend from the first end to the second end of the plate; wherein the at least one first header and / or the second header have a first height that is greater than a second height of the flow channels (40) and is substantially the same as a distance between terminals of adjacent battery cells when separated from one of the heat exchanger plates. [27] Heat exchanger plate according to claim 26, wherein at least one of the first head part and the second head part having the first height have opposing flat surfaces for contacting the terminals of the battery cells. [28] A heat exchanger plate according to claim 26 or 27, wherein the at least one first header comprises the fluid inlet header and the second header comprises the fluid outlet header and wherein each of the flow channels (40) extends between the fluid inlet header and the fluid outlet header. [29] Heat exchanger plate according to claim 28, wherein the fluid inlet header and / or the fluid outlet header have a first height greater than the second height of the flow channels (40) and substantially the same as the distance between the terminals of the adjacent battery cells when separated by a heat exchanger plate (12). [30] The heat exchanger plate of claim 26 or 27, wherein the at least one header comprises the fluid inlet header and the fluid outlet header, and wherein the second header comprises a diverter header (88), wherein the flow channels (40) include a first plurality of inlet flow channels extending from the inlet header to the diverter header and a plurality of outlet flow channels extending from the diverter header to the outlet header. [31] A heat exchanger plate according to claim 30, wherein the deflection header has a first height greater than the second height of the flow channels and substantially the same as the distance between the terminals of adjacent battery cells when separated by one of the heat exchanger plates. [32] A heat exchanger comprising a plurality of repeating units, each repeating unit comprising a first battery cell, a second battery cell adjacent to the first battery cell, and a heat exchanger plate according to any one of claims 27 to 31 adjacent to the second battery cell, wherein a gap is provided between the terminals of the first battery cell and the terminals of the second battery cell in each repeating unit, and wherein the gap is at least partially filled by an elongated filler strip. [33] A heat exchanger according to claim 32, wherein the elongated filler strip comprises a rod of resilient, deformable material. [34] A heat exchanger according to claim 32 or 33, wherein the heat exchanger includes a plurality of elongated filler strips, one of the filler strips being included for each repeating unit, and wherein the elongated filler strips of the repeating units are spaced apart from one another and are attached to a connecting member.

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