HEAT EXCHANGER

Abstract

Heat exchanger (10, 10', 10'') for thermal battery management applications, which features: a heat exchanger core defining at least one internal flow passage (24), wherein the at least one internal flow passage (24) has an inlet end (54, 54a), an outlet end (54b), at least one first flow passage region (24(1)) and at least one second flow passage region (24(2)), and the first and second flow passage regions are connected by a U-shaped turning region (26); an inlet distributor (42, 70) in fluid connection with the inlet end (54, 54a) of the inner flow passage for supplying an incoming fluid flow to the heat exchanger (10, 10', 10''); an outlet distributor (44, 72) in fluid connection with the outlet end of the inner flow passage for discharge of an outgoing fluid flow from the heat exchanger (10, 10', 10''); and at least one bypass passage (68, 68', 68''', 68'''') which fluidically connects the incoming fluid flow and the outgoing fluid flow, wherein the at least one bypass passage (68, 68', 68'''', 68'''') allows fluid from the incoming fluid flow to be diverted to the outlet distributor (44, 72) and at least partially bypasses the at least one internal flow passage (24) of the heat exchanger (10, 10', 10''); a base plate (14, 14') with a central, planar region (20) surrounded by a circumferential flange (22), wherein the at least one inner two-way flow passage (24) is formed within the central, planar region (20) of the base plate (14, 14'); a cover plate (16) which is arranged over and in sealing engagement with the base plate (14, 14') and which includes at least one enclosed the inner flow passage (24), wherein the cover plate (16) has a central, flat area (18) that defines a primary heat transfer surface of the heat exchanger (10, 10', 10''); wherein the cover plate (16) has at least one inlet opening (30) in fluid communication with the inlet distributor (42, 70) and with the inlet end (54, 54a) of the at least one internal flow passage (24), and has at least one outlet opening (32) in fluid connection with the outlet distributor (44, 72) and with the outlet end (54b) of the at least one internal flow passage (24); a distributor cover (40, 40', 40", 40''') which is arranged on and in sealing engagement with the cover plate (16) and defines at least partially the inlet and outlet distributor (70, 72); wherein at least one bypass passage (68, 68') connects the inlet distributor (70) and the outlet distributor (72) and which at least one bypass passage (68, 68') is arranged in the distributor cover (40, 40', 40'', 40''') is, wherein the distributor cover (40, 40', 40'', 40''') comprises an inlet distributor flow channel (70) in fluid communication with the at least one inlet opening (30) of the cover plate (16) for supplying an incoming heat exchange fluid to the inlet end (54, 54a) of the at least one inner flow passage (24) and an outlet distributor flow channel (72) in fluid communication with the at least one outlet opening (32) of the cover plate (16) for receiving the heat exchange fluid from the outlet end (54b) of the at least one inner flow passage (24), as well as a flow barrier (58, 58a, 58b, 60) arranged between the inlet and outlet distributor flow channels (70, 72), each bypass passage (68, 68') being formed by a gap (68, 68') is defined in the flow barrier (58, 58a, 58b, 60).

Description

CROSS-REFERENCE TO RELATED REGISTRATION

[0001] This application claims the priority and benefits of provisional US patent application No. 62 / 332 826, which was filed on May 6, 2016, and the contents of which are incorporated herein. TECHNICAL AREA

[0002] This disclosure relates to heat exchangers for use in thermal battery management with an integrated bypass, which provide additional control over the amount of fluid passed through the heat exchangers to achieve specific cooling effects and / or to meet specific pressure drop parameters for a particular application. BACKGROUND

[0003] Rechargeable batteries, such as those made up of many lithium-ion cells, can be used in a wide range of applications, including electric vehicles (EVs) and hybrid electric vehicles (HEVs). Lithium-ion batteries in electric or hybrid electric vehicles typically generate a significant amount of heat that needs to be dissipated, and therefore these types of batteries or battery systems require cooling to extend their lifespan.

[0004] Liquid-cooled heat exchangers, such as cold plate heat exchangers, can be used to manage the thermal load of the batteries used in these types of battery systems. Cold plate heat exchangers are heat exchangers on which a stack of adjacent battery cells or battery cell containers, each holding one or more battery cells, is arranged for cooling and / or temperature control of a battery unit. The individual battery cells or battery cell containers are generally arranged adjacent to one another in mutual surface contact to form the battery stack, with the stack of battery cells or battery cell containers positioned above the cold plate heat exchanger such that one end face of each battery cell or battery cell container is in surface contact with a surface of the heat exchanger.

[0005] Temperature uniformity across the surface of battery-cooling heat exchangers is a crucial aspect of the thermal management of these types of battery cells or complete battery systems. This uniformity ensures minimal temperature differences between individual battery cells within the overall battery unit. In electric and / or hybrid-electric vehicles with multiple battery packs of varying sizes, each pack does not generate the same thermal load, and therefore the coolant flow rate to each cold plate does not necessarily need to be identical.Therefore, since each heat exchanger or cold plate in the battery system does not require the same coolant flow rate, it may be desirable to divert a portion of the coolant flow past one or more heat exchangers within the system, with the aim of ensuring a more uniform temperature distribution and reducing the pressure drop within the overall system. Accordingly, heat exchangers with bypass structures are desirable and can be considered particularly useful for these types of applications.

[0006] Heat exchangers with bypass structures are known from the prior art. US 2014 / 0138075 A1, for example, describes a heat exchanger core with a two-way flow path, an inlet and outlet manifold, and a wide bypass channel. US 2016 / 0049705 A1 also describes a heat exchanger consisting of a base plate and a flat cover plate with inlet and outlet openings. DE 102011057190 A1 describes a heat exchanger with a bypass integrated in a manifold cover. Further design possibilities for such heat exchangers are disclosed in DE 66925067 T2, DE 102008035400 A1, and US 5042577 A. SUMMARY OF THE PRESENT DISCLOSURE

[0007] According to an embodiment of the present disclosure, a heat exchanger for use in thermal battery management is provided, comprising a heat exchanger core defining at least one internal two-way flow passage, wherein the at least one internal two-way flow passage has an inlet end and an outlet end and at least a first flow passage region and at least a second flow passage region connected to each other by a generally U-shaped reversing section; an inlet manifold in fluid communication with the inlet end of the internal flow passage for supplying an incoming fluid flow to the heat exchanger; and an outlet manifold in fluid communication with the outlet end of the internal flow passage for discharging a fluid flow exiting the heat exchanger.and a bypass passage that fluidically connects the incoming fluid flow and the outgoing fluid flow, wherein the bypass passage allows fluid from the incoming fluid flow to be diverted to the outlet manifold, bypassing the at least one internal two-way flow passage of the heat exchanger. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference is now made, by way of example, to the accompanying drawings, which show exemplary embodiments of the present application, and in which: Fig. 1 is a perspective view of a battery unit that includes an exemplary battery cooling counterflow heat exchanger without a bypass; Fig. 2 a top view of an exemplary base plate for use in the battery cooling heat exchanger according to Fig. 1 and in the battery cooling heat exchangers according to other embodiments disclosed herein; Fig. 3 is a top view of an exemplary battery cooling U-flow heat exchanger without a bypass; Fig. 4 A top view of an exemplary base plate for use in the battery cooling heat exchanger according to Fig. 3 is; Fig. 5 is a bottom view of a distributor structure with integrated bypass according to an embodiment of the present disclosure; Fig. 6 is a bottom view of a distributor structure with integrated bypass according to another embodiment of the present disclosure; Fig. 7 a top view of the distribution structure according to Fig. 5 containing battery cooling heat exchangers; Fig. 8 a detailed perspective view of the bypass area of ​​a distributor structure with integrated bypass according to another embodiment of the present disclosure; Fig. 9 a partial sectional view of a battery cooling heat exchanger with the distribution structure according to Fig. Figure 8 illustrates a first operating state; Fig. 10 a partial sectional view similar to the one in Fig. Figure 9 illustrates a second operating state; Fig. 11 is a schematic top view of a standard U-flow heat exchanger without an integrated bypass; Fig. 12 a schematic top view of a U-flow heat exchanger according to another embodiment of the present disclosure with integrated bypass; Fig. 13 A top view of a modified base plate with integrated bypass for use in a heat exchanger as in Fig. 1 is shown; Fig. 14 is a perspective view of a U-flow heat exchanger according to another embodiment; Fig. 15 a skewed perspective view of the heat exchanger according to Fig. 14 is; and Fig. 16 a top view of the base plate of the U-flow heat exchanger according to Fig. 14 is.

[0009] Similar reference numbers can be used in different figures to denote identical components. DESCRIPTION OF EXAMPLES OF EXECUTION

[0010] Fig. Figure 1 shows an illustrative example of a rechargeable battery unit 100 that uses a battery cooling heat exchanger 10. The battery unit 100 consists of an array of individual battery cell containers 12, each of which can hold one or more battery cells (not shown). As shown, the battery cooling heat exchanger (or cold plate heat exchanger) 10 is arranged beneath the one or more stacks 11 of battery cells or battery cell containers 12.Accordingly, the multiple battery cells or battery cell containers 12 in each stack 11 are arranged adjacent to each other in mutual surface contact to form the stack 11, the stack of battery cells or battery cell containers 12 then being arranged on the cold plate heat exchanger 10 such that an end surface of each battery cell or battery cell container 12 is in surface contact with a primary heat transfer surface 13 of the heat exchanger 10.

[0011] The heat exchanger 10 is formed from two main heat exchanger plates, namely a shaped base plate 14 and a generally flat cover plate 16. The cover plate 16 has a central, generally flat area 18, which provides a generally flat surface on which the individual battery cells or battery cell containers 12 are stacked. The central, generally flat area 18 of the cover plate 16 therefore serves as the primary heat transfer surface 13 for the battery cooling heat exchanger 10.

[0012] The base plate 14 is also provided with a central, generally flat region 20, which is surrounded by a raised circumferential flange 22. The central, generally flat region 20 of the base plate 14 is provided with several mutually spaced ribs 28, which define several fluid flow passages 24. The ribs 28 extend upwards from the plane of the central, generally flat region 20 and have a sufficient height such that the upper surface of each rib 28 is substantially coplanar with the circumferential flange 22.Thus, during the assembly of the heat exchanger 10, the circumferential flange 22 and the upper surfaces of the fins 28 are sealed to the cover plate 16, so that the cover plate 16 defines the upper walls of the fluid flow passages 24, the central, generally flat area 20 of the base plate 14 defines the lower walls of the fluid flow passages 24, and the side walls of the fins 28 and the circumferential flange 22 define the sides of the fluid flow passages 24. The upper surfaces of the fins 28 can be flat or rounded.

[0013] The fluid flow passages 24 of the base plate 14 can have various configurations. In the embodiments disclosed herein, the inlet and outlet of the heat exchanger 10 (described in more detail below) are located at the same end of the heat exchanger, and therefore the fluid flow passages 24 are configured such that the cooling fluid flows from the inlet to the opposite end of the heat exchanger 10 and then back to the outlet. Thus, in the embodiments described herein, the base plate 14 is configured for a "U-flow" or a "counterflow," such that the cooling fluid completes two passages along the length of the base plate 14 when flowing from the inlet to the outlet.

[0014] The in the Fig. The illustrated embodiment 1-2 is configured for a counterflow of the coolant through the fluid flow passages 24. Battery cooling counterflow heat exchangers are described in the applicant's pending US application No. 14 / 972463, filed on December 17, 2015, and published on July 14, 2016, as US 2016 / 0204486A1, the contents of which are hereby incorporated. In the battery cooling counterflow heat exchanger 10, the base plate 14 has a first end 34 and a second end 36, which are spaced apart longitudinally, with the inlet and outlet being defined near the first end 34. Similarly, the ribs 28 of the base plate 14 each have a first end 37 near the first end 34 of the base plate 14 and an opposite second end 38 near the second end 36 of the base plate 14.In the present embodiment, the ribs 28 of the base plate 14 are straight, however this is not essential and depends on the requirements of the specific application.

[0015] The base plate 14 in the embodiment of the Fig. 1 and Fig. 2 has two types of ribs 28: (a) several first ribs 28(1), each of whose first end 37 is spaced a distance from the circumferential flange 22 at the first end 34 of the base plate 14, and each of whose second end 38 is spaced a distance from the circumferential flange 22 at the second end 36 of the base plate 14; and (b) several second ribs 28(2), each of whose first end 37 is spaced a distance from the circumferential flange 22 at the first end 34 of the base plate 14, and each of whose second end 38 is connected to the circumferential flange 22 at the second end 36 of the base plate 14. The first and second ribs 28(1) and 28(2) are arranged in alternating order over the width of the base plate 14, the first end 37 of each first rib 28(1) being connected to the first end 37 of an adjacent second rib 28(2) by a transverse rib region 39.

[0016] As from the Fig. 1 and Fig. As can be seen in Figure 2, the base plate 14 has a first distribution area 54, defined at its first end 34, between the circumferential flange 22 and the first ends 37 of the ribs 28(1) and 28(2), which are connected by transverse rib areas 39. The first distribution area 54 extends continuously over substantially the entire width of the base plate 14. Several reversal areas 26 are also located at the second end 36 of the base plate 14, each reversal area 26 situated between the circumferential flange 22 and the second end 38 of one of the first ribs 28(1). The reversal areas 26 are separated from each other by the second ribs 28(2), which are connected to the circumferential flange 22 at their second ends 38.

[0017] With this arrangement of the first and second ribs 28(1) and 28(2), the base plate 14 defines several first fluid flow passages 24(1), each extending between the first distributor region 54 and one of the turning regions 26; and several second fluid flow passages 24(2), each extending between one of the turning regions 26 and one of the transverse rib regions 39, which connect the first ends 37 of an adjacent pair of ribs 28(1), 28(2). The first and second fluid flow passages 24(1), 24(2) alternate across the width of the base plate 14, thereby defining the counterflow configuration of the base plate 14.

[0018] The cover plate 16 of the heat exchanger 10 is provided with one or more first openings 30 and several spaced-apart second openings 32 to provide a fluid inlet and outlet to and from the fluid flow passages 24. In the heat exchanger 10, the one or more first openings 30 define an inlet to the several first fluid flow passages 24(1), and the several second openings 32 define an outlet of the several second fluid flow passages 24(2). In the illustrated embodiment, the one or more first openings 30 have a continuous slot located directly above the first distributor area 54 of the base plate 14.Fluid entering the first distributor section 54 through one or more first openings 30 is distributed along the length of the first distributor section 54 to each of the first fluid flow passages 24(1) and flows to the second end 36 of the base plate 14, changes direction in the reversal sections 26, and then flows back to the first end 34 of the base plate 14. Each of the spaced-apart second openings 32 is located directly above one of the second fluid flow passages 24(2) near a transverse fin section 39 and the second ends 38 of the fins 28. In this way, cooling fluid flowing through each of the second fluid flow passages 24(1) exits the heat exchanger 10 through one of the spaced-apart second openings 32.

[0019] The heat exchanger 10 further comprises a distributor cover 40, which is positioned above the cover plate 16 directly above the first and second openings 30, 32. The distributor cover 40 has an elongated structure and extends transversely across the cover plate 16. The distributor cover 40 has a circumferential flange 46 that surrounds a pair of mutually spaced beads 42, 44, each having a longitudinal axis extending transversely across the cover plate 16. The flange 46 defines a lower, flat sealing surface that seals against a region of the cover plate 16 surrounding the first and second openings 30, 32. The beads 42, 44 are raised relative to the flange 46 and form an inlet and outlet distributor, respectively.The first bead 42 is located directly above one or more first openings 30 of the cover plate 16 and the first distributor area 54 of the base plate 14, thus defining an inlet distributor in the present embodiment. The second bead 44 is located directly above the several spaced-apart second openings 32 and the ends of the second fluid flow passages 24(2) near the transverse rib areas 39, thus defining an outlet distributor.

[0020] The first and second beads 42, 44 are separated from each other by a flat intermediate section 48, which extends transversely between the pair of beads 42, 44 and has a lower surface that is sealedly connected to a region of the cover plate 16 extending along a transverse line between the one or more first openings 30 and the several spaced-apart openings 32. In the present embodiment, the lower surface of the intermediate section 48 is continuous and is connected at its opposite ends to the circumferential flange 46 in order to completely separate the beads 42, 44 from each other. Therefore, there is no fluid connection between the beads 42, 44, except through the fluid flow passages 24, and therefore no bypass flow.

[0021] Accordingly, when the distributor cover 40 is arranged on the cover plate 16, the first and second beads 42, 44 each form an open internal distributor space for supplying / discharging the heat exchange fluid to / from the flow passages 24 via the first and second openings 30, 32. A fluid opening 50, 52 is provided in each bead 42, 44 to provide fluid access to the open internal spaces defined by the first and second beads 42, 44 when the distributor cover 40 is arranged in a sealing, paired relationship with the cover plate 16. The fluid opening 50 formed in the bead 42 provides an inlet opening, and the fluid opening 52 in the bead 44 provides an outlet opening. The fluid openings 50, 52 can be fitted with tubular inlet and outlet fittings 51, 53 for connection to the coolant circulation system (not shown) of the vehicle.

[0022] The fluid openings 50, 52 can each be formed at any point along the length of the respective bead 42, 44 such that they correspond to the specific locations desired for the inlet and outlet fittings of the heat exchanger 10 based on specific consumer or application requirements. Fig. Figure 1 illustrates both the inlet and outlet openings 50, 52 arranged on the same side of the heat exchanger 10, but it should be noted that the openings 50, 52 can be positioned anywhere along the longitudinal axes of the ridges 42, 44. Accordingly, in the Fig. 1 and Fig. In the embodiment shown in Figure 2, fluid enters the bead 42 through the inlet fitting 51 and the fluid opening 50, where it moves along the open inner space formed beneath the bead 42 to one or more first openings 30. These openings are formed in the cover plate 16, located directly above the first distributor section 54, and are in fluid contact with the inlet ends of the first flow passages 24(1). The fluid then moves through the first flow passages 24(1), changes direction in the reversal sections 26, and enters the second flow passages 24(2).The fluid then flows through the second flow passages 24(2) in a direction opposite to the flow direction in the first flow passages 24(1) and exits the second flow passages 24 through the several second openings 32 in the cover plate 16, from where it then moves through the open inner space formed by the bead 44 and is discharged through the outlet opening 52 and the outlet fitting 53.

[0023] The one in the Fig. 3 - 4 illustrated heat exchanger 10' is configured for a U-flow of the coolant through a U-shaped fluid flow passage 24. In the Fig. 3 and Fig. In section 4 and the following description, identical elements of the heat exchangers 10, 10' are identified by identical reference numerals, and the provided description of these identical elements is applicable to the present embodiment.In this embodiment, the base plate 14 has two types of ribs 28: (a) several first ribs 28(1), each with a first end 37 spaced apart from the circumferential flange 20 at the first end 34 of the base plate 14, and a second end 38 spaced apart from the circumferential flange 22 at the second end 36 of the base plate 14; (b) several second ribs 28(2) with the same configuration as the first ribs 28(1); and (c) a dividing rib 28(3) located between the multiple first and second ribs 28(1), 28(2), the dividing rib 28(3) having a first end 37 connected to the circumferential flange 22 at the first end 34 of the base plate 14 and a second end 38 spaced apart from the circumferential flange 22 at the second end 36 of the base plate 14. The dividing rib 28(3) is here sometimes also referred to as a flow barrier 89.

[0024] With this arrangement, the central, generally flat region 20 of the base plate 14 defines a generally U-shaped flow passage 24 with a first flow passage region 24(1), defined by the multiple first ribs 28(1), and connected to a second flow passage region 24(2) by a generally U-shaped reversal region 26. The first flow passage region 24(1) is separated from the second flow passage region 24(2), or fluidically isolated from it, by the flow barrier 89, which extends between the two flow passage regions 24(1) and 24(2) and is defined by the dividing rib 28(3). The U-shaped flow passage 24 is formed such that it is recessed relative to the plane of the base plate 14 or extends downwards from it, whereby the circumferential flange 22 lies in a different plane than that of the flow passage 24.Accordingly, when the base plate 14 and the cover plate 16 are arranged in their paired relationship, the flow passage 24 between them is enclosed. The upper surface of the fins 28 is essentially coplanar with the circumferential flange 22 in order to be sealed against the cover plate 16 in the same manner as the fins 28 of the previously described counterflow heat exchanger 10, and may have flat or rounded upper surfaces.

[0025] A first distributor area 54 is defined at the first end 34 of the base plate 14 between the first ends 37 of the ribs 28(1), 28(2) and the circumferential flange 22. Since the first end 37 of the dividing rib 28(3) or flow barrier 89 is connected to the circumferential flange 22, the first distributor area 54 is divided into two segments 54a, 54b, which are fluidically isolated from each other. The first segment 54a of the first distributor area 54 is in fluid communication with all channels that form the first flow passage area 24(1), while the second segment 54b of the first distributor area 54 is in fluid communication with all channels that form the second flow passage area 24(2).The dividing rib 28(3) or flow barrier 89 has a second end 38 which is spaced from the circumferential flange 22 at the second end 36 of the base plate 14, and therefore the generally U-shaped reversing region 26 extends continuously over substantially the entire width of the base plate 14, provides a fluid connection between the two flow passage regions 24(1), 24(2) and defines a continuous second distributor region at the second end 36 of the base plate 14, which is in fluid communication with all channels of the first and second flow passage regions 24(1), 24(2).

[0026] To enable fluid access to the flow passage 24, one or more first fluid openings 30 and one or more second fluid openings 32 are formed in the cover plate 16 such that, when the base plate 14 and the cover plate 16 are arranged in their paired relationship, the one or more first openings 30 provide fluid access to an inlet end of the flow passage 24, e.g., segment 54a of the first distributor section 54 and the first flow passage section 24(1), to supply heat exchange fluid (e.g., liquid coolant) to the heat exchanger 10, while the one or more second fluid openings 32 provide fluid access to an outlet end of the flow passage 24, e.g., segment 54b of the first distributor section 54 and the second flow passage section 24(2), to discharge the heat exchange fluid from the heat exchanger 10.More precisely, the one or more first openings 30 are located directly above the first flow passage area 24(1) on the right side of the flow barrier 89 near the first end 34 of the base plate 14, and the one or more second openings 32 are located directly above the second flow passage area 24(2) on the left side of the flow barrier 89 near the first end of the base plate 14. Each of the one or more first and second openings 30, 32 can have a single opening, an elongated slot, or several spaced-apart openings, as shown in . Fig. 3 is shown. As in Fig. As shown in Figure 3, the one or more first openings 30 are arranged directly above only the first flow passage area 24(1), while the one or more second openings 32 are arranged directly above only the second flow passage area 24(2).

[0027] A distributor cover 40 is arranged above the cover plate 16 over the one or more first and second openings 30, 32. In the present embodiment, the distributor cover 40 is shown to be identical to the distributor cover 40 of the one shown in the Fig. 1 and Fig. The heat exchanger 10 shown in Figure 2 contains the connection fittings 51, 53. When the distributor cover 40 is arranged above the cover plate 16, the first and second beads 42, 44 each form an open inner space for supplying / discharging the heat exchange fluid to / from the U-shaped flow passage 24 via one or more of the first and second openings 30, 32.

[0028] The provision of the distributor cover 40 allows the fluid openings 50, 52 to be formed at any point along the length of the respective bead 42, 44. However, it should be noted that the distributor cover 40 is optional in the present embodiment. For example, a single first opening 30 can be arranged directly above the first flow passage area 24(1), and a single second opening 32 can be arranged directly above the second flow passage area 24(2), and the connecting fittings 51, 53 can be attached directly to the cover plate 16 and sealed with the openings 30, 32, as shown in the Fig. 14. In such an embodiment, which does not include the distributor cover 40, the openings 30, 32 can be arranged in ridges formed on the cover plate 16, the ridges being located on each side of the flow barrier 89.

[0029] In the present embodiment, cooling fluid entering the heat exchanger 10 passes through the inlet fitting 51 and the fluid opening 50 in the bead 42, from where it moves along the open inner space formed beneath the bead 42 to one or more first openings 30 formed in the cover plate 16, which corresponds to the inlet end of the first flow passage region 24(1). The fluid then moves along the first flow passage region 24(1), as indicated by the flow direction arrows in Fig. Figure 4 illustrates the process before the fluid flows through the continuous U-shaped reversal zone 26, which is formed at the opposite end of the heat exchanger 10, from where it enters the second flow passage 24(2). The fluid then flows along the second flow passage 24(2) in a direction opposite to the flow direction in the first flow passage 24(1), and then exits the flow passage 24 through one or more second openings 32 in the cover plate 16, from where it then moves through the open inner space formed in the bead 44, from which it is discharged through the outlet opening 52 and the outlet fitting 53. As in the previously described embodiment, the beads 42 and 44 are completely separated from each other by the intermediate zone 48.Therefore, there is no fluid connection between the beads 42, 44, except through the fluid flow passage 24, and no bypass flow is present.

[0030] In the Fig. 5 and Fig. Figure 7 shows a modified distributor cover plate 40' according to an embodiment of the present disclosure, which includes a bypass structure to assist in determining the quantity of heat exchange fluid (e.g., liquid coolant) that is passed through the internal flow passage(s) 24 within the heat exchanger 10, wherein the flow passage(s) 24 can be configured for counterflow or U-flow as described above. Fig. In Section 5 and the following description, identical elements are identified by identical reference numerals, and the preceding description of these identical elements is applicable to the present embodiment. In addition to its use instead of the distributor cover 40 described above, the distributor cover 40' can be used instead of the distributor plate(s) or distributor cover(s) described in conjunction with the embodiments described in the Fig. 3 - 6; the Fig. 7 - 9; the Fig. 12 - 19 and the Fig. The battery cooling heat exchanger shown in the applicant's pending US application No. 14 / 972 463 is used.

[0031] In some applications, it is not necessary for all of the available heat exchange fluid or liquid coolant to pass through the battery cooling heat exchanger 10, as the amount of cooling required may depend on the amount of heat generated by a particular battery pack 11 within the overall system or vehicle. Likewise, if it is desirable to minimize the overall pressure drop through the battery cooling system, it may be advantageous to incorporate a mechanism that allows some of the fluid to be diverted away from the heat exchanger and that controls the amount of fluid directed to the flow passage(s) 24 of the battery cooling heat exchanger 10.

[0032] Instead of using two separate ridges 42, 44 separated by a circumferential flange 46 and the intermediate region 48 to provide two distinct and separate open internal spaces serving as inlet and outlet distributors, respectively, the distributor cover 40' has an inverted bowl-shaped structure with a raised central, generally flat region or main ridge 56 surrounded by a circumferential flange 46. In the present embodiment, a first and a second flow barrier 58, 60 are formed within the boundaries of the main ridge 56 and are directed downwards or recessed with respect to the raised central, generally flat region or main ridge 56. Accordingly, the first and second flow barriers 58, 60 each have a bottom or lower surface that generally lies in the same plane as the circumferential flange 46.As a consequence, the circumferential flange 46 and the first and second flow barriers 58, 60 are in sealing contact with the cover plate 16 when it is arranged on it, thus obtaining an enclosed distributor structure.

[0033] Both the first and second flow barriers 58, 60 are arranged and generally extend along the central or longitudinal axis of the raised central, generally flat area or main bead 56 of the distributor cover 40' and are spaced apart from the respective ends 62, 64 therefrom. Like the intermediate area 48 of the distributor cover 40, the flow barriers 58, 60 extend transversely along the cover plate 16, their lower surfaces sealingly connected to an area of ​​the cover plate 16 extending along a transverse line between the one or more openings 30 and the multiple spaced-apart openings 32.The first flow barrier 58 extends from near the first end 62 of the raised central, generally flat region or main bead 56 of the distributor cover 40' over a first length or distance along its longitudinal axis, while the second flow barrier 60 extends from near the second or opposite end 64 of the raised central, generally flat region or main bead 56 of the distributor cover 40' over a second length or distance along its longitudinal axis. In the present embodiment, the first length associated with the first flow barrier 58 is greater than the second length associated with the second flow barrier 60.As a consequence of the different lengths of the first and second flow barriers 58, 60, the first and second flow barriers 58, 60 have a mutual distance d along the central or longitudinal axis of the raised central, generally flat area or main bulge 56, forming a gap or bypass channel 68 between them. While the first flow barrier 58 has a greater length than the second flow barrier 60, thus forming a bypass channel 68 with a certain width d, it should be noted that the actual lengths of the respective flow barriers 58, 60 and the resulting actual size / width of the bypass channel 68 formed between them can vary in order to achieve a specific flow rate through the distributor structure, as discussed in detail below.

[0034] The fluid openings 50, 52 are formed in the raised central, generally flat area or main ridge 56 of the distributor cover 40', with one of the openings 50, 52 being formed on one side of the flow barriers 58, 60 and the other of the openings 50, 52 being formed on the opposite side of the flow barriers 58, 60. Accordingly, the first and the second flow barriers 58, 60 form a first distributor flow channel 70 on one side thereof and a second distributor flow channel 72 on the other side thereof, the first distributor flow channel 70 being in direct fluid communication with one of the fluid openings 50, 52 formed therein and the second distributor flow channel 72 being in direct fluid communication with the other of the fluid openings 50, 52.However, due to the special arrangement of the first and second flow barriers 58, 60, the first and second distributor flow channels 70, 72 are not fluidly isolated from each other as in the case of the one in the . Fig. The distributor cover 40 shown in Figures 1 to 4 is not connected to each other by the bypass channel 68 and at the gaps 67, 69, which are formed at the respective ends 62, 64 of the raised central, generally flat area or main ridge 56 around the corresponding ends of the first and second flow barriers 58, 60. Therefore, while fluid enters the heat exchanger 10 through the inlet opening 50 formed in the distributor cover 40' and is distributed to the inner flow channels 24 enclosed within the heat exchanger 10, this incoming fluid can also be directed directly to the fluid outlet opening 52, located in the second distributor flow channel 72, through the bypass channel 68, which effectively bypasses the inner flow passages 24 of the heat exchanger 10.The incoming fluid can also be directed directly through the gap 67, 69 to the second distributor flow channel 72, which is formed between the ends 62, 64 of the raised central, generally flat area or main bead 56 and the corresponding adjacent end of the first or second flow barrier 58, 60.

[0035] The fluid openings 50, 52 can be arranged at any point along the first and second distributor flow channels 70, 72, respectively, depending on the desired location for the external inlet and outlet connections of the heat exchanger 10. The locations of the fluid openings 50, 52 can also be specifically selected in relation to the specific location of the bypass channel 68 to achieve the desired flow pattern through the distributor 40' and the heat exchanger 10 and / or to maintain or minimize a specific pressure drop through the overall battery cooling system.

[0036] Fig. 7 shows the distributor cover of Fig. 5 in a heat exchanger 10 comprising a counterflow base plate 14 and a cover plate 16, which are identical to those with reference to the Fig. 1 and Fig. 2 described, and the preceding description of these components applies in the same way to the heat exchanger 10 in Fig. 7 applicable.

[0037] Fig. Figure 6 shows a distributor cover 40" according to another embodiment, which is identical to the distributor cover 40' described above, except that the gaps 67, 69 are eliminated, and each of the flow barriers 58, 60 is connected to the circumferential flange 46. Additionally, the first flow barrier 58 is divided into two segments 58a, 58b, separated by a gap 68'. It should be noted that there are many different configurations of distributor covers 40 that are within the scope of this disclosure, i.e., with or without one or both gaps 67, 69 and / or containing two or more segments to provide two or more bypass gaps 68. According to an alternative configuration of the distributor cover 40, the flow barriers 58, 60 can be connected end-to-end to eliminate the bypass gap 68, while one or both Columns 67 and 69 are provided for.The exact configuration of the distributor cover 40 depends at least partially on the desired size of the bypass flow and on the desired locations for the fluid openings 50, 52 and the fittings 51, 53.

[0038] In the Fig. Figures 8-10 show another embodiment of a manifold structure that includes a bypass for use with a battery cooling heat exchanger 10, 10' with U-flow or counterflow as described above. Instead of including a previously described manifold cover 40' or 40" with a bypass channel 68 and / or one or more columns 67, 69, the heat exchanger 10 according to the present embodiment includes a manifold cover 40''' together with a thermal bypass valve component 80 to provide an integrated bypass. The manifold cover 40''' can be installed on any of the previously described counterflow or U-flow heat exchanger 10.

[0039] The distributor cover 40''' is structurally similar to the one described above with reference to the Fig. The distributor cover 40 described in Sections 1-4 is formed with a first and a second bead 42, 44, each forming an open inner space between the inner surface of the distributor cover 40 and the cover plate 16 or outer surface of the heat exchanger 10, which serve as the first and second distributor flow channels 70, 72. However, since the first and second distributor flow channels 70, 72 are formed by separate bead 42, 44, the first and second distributor flow channels are separated by the intermediate area 48 or arranged at a distance from each other. A fluid opening 50, 52 is formed in each of the bead 42, 44 to provide fluid access to each of the first and second distributor flow channels 70, 72. The bead 42, 44 that serves as the inlet distributor, for example, the bead 42 in the Fig. In the illustrated embodiment shown in Figures 8-10, the bypass opening 74 is also provided with a second fluid opening 74, which serves as a bypass opening, wherein the bypass opening 74 has a distance in the longitudinal direction of the bead 42 from the fluid inlet opening 50 and is arranged opposite to the fluid outlet opening 52, which is formed in the adjacent bead 44, which forms a second distributor flow channel 72.

[0040] The thermal bypass valve 80 consists of an outer housing 82 with an inner valve chamber 83 formed therein for receiving a valve mechanism 84. A first fluid port 85 has a first end in fluid communication with the bypass port 74 formed in the distributor cover 40''' and extends into the outer housing 82, the first fluid port 85 having a second end in fluid communication with the inner valve chamber 83. A second fluid port 86 has a first end in fluid communication with the fluid outlet port 52 formed in the distributor cover 40''' and extends through the outer housing 82, through the inner valve chamber 83 to the outlet fitting 87. The valve mechanism 84 serves to control the flow from either the bypass port 74 and / or the fluid outlet port 52 through the inner valve chamber 83 to the outlet fitting 87.The valve mechanism 84 can be operated either by a passive wax motor or by an active solenoid valve or any other suitable means known in the prior art. The valve mechanism 84 has a first, normally open position (in . Fig. 9), in which the bypass opening 74 is open, allowing the fluid to move from the inlet manifold and the first manifold flow channel 70 through the bypass opening 74 to the inner valve chamber 83, from which it is directed from the valve component 80 to the outlet fitting 87. When the temperature of the fluid discharged from the heat exchanger 10 through the fluid outlet opening 52 increases, the valve mechanism 84 is activated, closing the first fluid opening 85 and the bypass opening 74 until the Fig. The fully closed or second operating position shown in Figure 10 is reached. As the first fluid port 85 and the bypass port 74 are progressively closed by the action of the valve mechanism 84, more and more fluid is directed through the inner flow passage(s) 24 of the heat exchanger 10, thereby reducing the amount of bypass fluid. After the first fluid port 85 and the bypass port 74 are completely closed, all the fluid entering the heat exchanger 10 through the inlet fitting 88 is directed through the first distributor flow channel 70 to the inner flow passage(s) 24. The fluid is then moved through the flow passage(s) 24 before being directed to the second distributor flow channel 72, which in turn directs the fluid from the heat exchanger 10 to the outlet fitting 87 through the fluid outlet port 52 and the second fluid port 86 formed in the valve component 80.

[0041] When the valve component 80 is controlled by a wax motor, if the coolant temperature at the outlet fitting 87 is too high based on a predetermined set point or a temperature defined by the wax type, the wax expands to actuate the valve mechanism 84, causing the first fluid opening 85 and the bypass opening 74 to close, and causing the flow through the heat exchanger 10 to increase, thus cooling the corresponding battery cells or battery cell containers 12.If the coolant temperature at the outlet fitting 87 is too low based on predefined parameters, the wax contracts and the valve mechanism 84 opens the first fluid port 85 and the bypass port 74. This causes less coolant to pass through the heat exchanger 10, as more fluid is allowed to flow directly to the outlet 87 through the bypass port 74. In other configurations, the valve component 80 can be electronically controlled using a solenoid valve mechanism and a temperature sensor, which may be installed, for example, within the fluid flow of the outlet fitting 87, or a temperature sensor attached to the surface of the outlet fitting 87.

[0042] By incorporating a valve mechanism 84 into the bypass arrangement of the distributor structure 40''', additional control of the magnitude of the bypass flow permitted during the use / operation of the heat exchanger 10 is obtained, based on the temperature of the fluid flowing through the heat exchanger 10. As in the previously described embodiments, the specific location of the inlet and outlet fittings 87, 88 can be selected to be at any point along the respective ridges 42, 44; however, the bypass opening 74 must be arranged relative to the outlet opening 52 in the adjacent ridge 44 such that the valve component 80 can be in fluid communication with each of these openings 52, 74.In the illustrated embodiment, the openings 74 and 52 are arranged directly opposite each other, but this may not be necessary in all embodiments, depending on the structure of the valve component 80.

[0043] The Fig. Figures 11-13 show a battery cooling heat exchanger 10 with an integrated bypass structure according to another embodiment of the present disclosure. In the present embodiment, instead of the bypass features being directly associated with the distributor structure 40', 40", 40''' as in the embodiments described above, the inner flow passages 24 of the heat exchanger 10 itself can be provided with an integrated bypass feature that allows a fluid connection between the flow passages 24(1) associated with a first passage of the heat exchanger 10 and the flow passages 24(2) associated with the second passage or a return flow of the heat exchanger 10 (e.g., the incoming and outgoing flow channels).

[0044] Fig. Figure 11 is a schematic illustration of the internal flow path structure for a standard U-flow heat exchanger 10, in which the incoming fluid passes through a first flow passage region 24(1) similar to that described in the Fig. In the embodiment shown in Figures 2-4, the flow is directed to a U-shaped reversal section 26, in which it is reversed by approximately 180 degrees, and then through a second flow passage section 24(2) to the outlet distributor, from which it is discharged from the heat exchanger 10. A flow barrier 89 (also referred to above as a dividing rib 28(3)) separates the first flow passage section 24(1) from the second flow passage section 24(2).

[0045] Fig. Figure 12 shows a schematic illustration of a modified U-flow heat exchanger 10 with an integrated bypass feature according to an embodiment of the present disclosure. As shown, a bypass channel 68''' is formed in the flow barrier 89 to establish a fluid connection between the first flow passage region 24(1) and the second flow passage region 24(2) at a location further upstream (i.e., closer to the first end 34 of the base plate 14) than the actual U-reversal region 26. Accordingly, the fluid moving through the first flow passage region 24(1) on the inlet side can be diverted directly to the second flow passage region 24(2) on the outlet side by means of the bypass channel 68''' without terminating its complete passage through the heat exchanger 10.

[0046] Fig. 13 shows a modified base plate 14', which is in the Fig. The counterflow heat exchanger 10 shown in 1 can be used, wherein the modified base plate 14' has an integrated bypass feature that is inserted into the internal fluid flow passages 24 themselves, similar to the one described above in conjunction with Fig. 12 U-flow heat exchangers described. With the exception of the integrated bypass feature described below, the base plate 14' is in Fig. 13 essentially identical to the one in Fig. The two shown, and the same reference numbers are used to describe identical elements of the base plate 14'. The preceding description of the identical elements in the base plate 14 according to the Fig. 1 and Fig. 2 is applicable to the base plate 14', unless otherwise indicated below.

[0047] As in Fig. As shown in Figure 13, the integrated bypass feature of the base plate 14' has a bypass channel 38'''' which extends transversely to the flow direction of the first and second flow channels 24(1), 24(2), i.e., across the width of the base plate 14', and establishes a fluid connection between the multiple first fluid flow passages 24(1) and the multiple second fluid flow passages 24(2) at a location further upstream (i.e., closer to the first end 34 of the base plate 14') than the reversal areas 26 located at the second end 36 of the heat exchanger 10 and the base plate 14. Accordingly, the bypass channel 68'''' is formed such that it is located near, but at a distance from, the distributor end of the heat exchanger 10, i.e., the first end of the base plate 14.Therefore, the incoming fluid, which is directed to the multiple first fluid flow passages 24(1) through the first distributor flow channel 70 via the inlet opening 50 formed in the first bead 42 and the slot 30 formed in the cover plate 16, begins to move downwards through the multiple first fluid flow passages 24(1). When the fluid reaches the bypass channel 68'''', a portion of the fluid can "short-circuit" the main flow path through the heat exchanger 10 and is diverted directly to the multiple second fluid flow passages 24(2) near the outlet end (i.e., the first end 34) of the heat exchanger 10, instead of passing through the entire length of the multiple first fluid flow passages 24(1).Therefore, only a portion of the incoming heat exchange fluid passes through the entire length of the multiple first fluid flow passages 24(1) up to the reversal zones 26 before flowing back along the heat exchanger 10 through the multiple second fluid flow passages 24(2). By providing a bypass channel 68'''' directly in the structure of the base plate 14, which forms the flow channels 24(1), 24(2), an excessive pressure drop can be avoided, as incoming fluid can be discharged directly to the outlet before completing a full passage through the heat exchanger 10.

[0048] In the exemplary embodiment of Fig. 13 The integrated bypass feature of the base plate 14' has a continuous bypass channel 68'''' formed by providing gaps in all ribs 28 of the base plate 14', the gaps being oriented transversely to each other across the width of the base plate 14'. However, it should be noted that it is not essential that the integrated bypass feature has exactly this configuration. For example, in other embodiments, the integrated bypass feature may include the provision of gaps in only some of the ribs 28. For example, in other embodiments, the gaps may be formed in some or all of the first ribs 28(1) and / or some or all of the second ribs 28(2), and the gaps may be staggered relative to each other so that they are not oriented transversely to each other along the width of the base plate 14'.

[0049] The Fig. Figures 14-16 show a modified U-flow heat exchanger 10", which incorporates an integrated bypass feature in its base plate 14, in accordance with the schematic illustration of the Fig. 12. In the Fig. In references 14 - 16 and the following description, identical elements of the heat exchanger 10" are identified by identical reference numbers, and the preceding description of these identical elements in connection with the heat exchangers 10, 10' is applicable to the present embodiment.

[0050] The 10" heat exchanger has a base plate 14 configured for U-flow, but differs from the base plate 14 of the 10' heat exchanger in that it is generally L-shaped due to application requirements. Accordingly, the base plate 14 of the 10" heat exchanger includes an L-shaped circumferential flange 22, L-shaped fins 28, and an L-shaped flow barrier 89 or dividing fin 28(3) that divides the base plate into a first flow passage area 24(1) and a second flow passage area 24(2), both of which are L-shaped. The first end 34 of the base plate 14 in the Fig. 14 - 16 is the end of the base plate 14 where the inlet and outlet are located, while the second end 36 of the base plate 14 is angled at 90 degrees relative to the first end 34 and is located at the right end of the base plate 14.

[0051] The L-shaped first and second flow passage regions 24(1), 24(2) each contain several first ribs 28 and several second ribs 28(2), each of the ribs 28 having a first end 37 located at a distance from the circumferential flange 22 at the first end 34 of the base plate 14, and a second end 38 located at a distance from the circumferential flange 22 at the second end 36 of the base plate 14.

[0052] The base plate 14 of the heat exchanger 10" also differs from that of the heat exchanger 10' in that it lacks a continuous U-shaped reversal region 26 at its second end 36. Instead, the second ends 38 of the fins 28 are connected to each other by transverse fin regions 90 such that they define a series of nested U-shaped or L-shaped fluid flow passages 24a, 24b, 24c, 24d, each of which extends through the first and second flow passage regions 24(1), 24(2). Each of the fluid flow passages 24a, 24b, 24c, 24d contains a reversal region 26 in which the fluid flow changes direction between the first and second flow passage regions 24(1), 24(2).

[0053] The heat exchanger 10" also includes a cover plate 16 with an L-shape corresponding to that of the base plate 14. Instead of having one or more first and second fluid openings 30, 32 defined by a slot or several spaced-apart openings, the cover plate 16 of the heat exchanger 10" includes a single first opening 30 and a single second opening 32, both formed as circular holes.

[0054] The heat exchanger 10" also differs from the previously described heat exchangers 10, 10' in that it lacks a distributor cover 40. Instead, tubular fittings 51, 53 are attached directly to the first and second openings 30, 32 in the cover plate 16. An inlet and outlet distribution space for fluid distribution is provided by an inlet and outlet distribution space 54a, 54b at the first end of the base plate 14, i.e., between the first ends 37 of the fins 28 and the circumferential flange 22 at the first end 34. However, it should be noted that the heat exchanger 10" can be provided with a distributor cover 40 without an integrated bypass, as described above with reference to the Fig. As described in Figures 1-4, this allows, for example, greater flexibility regarding the locations of the openings 50, 52 and the fittings 51, 53. Alternatively, as discussed above, the cover plate 16 can be provided with ridges surrounding each of the openings 30, 32.

[0055] The heat exchanger 10" also includes a second cover plate 92, which is arranged above the central, generally flat area 18 of the cover plate 16, which defines the primary heat transfer surface 13.

[0056] The integrated bypass feature of the 10" heat exchanger is in the same manner as above with regard to the Fig. 12 described in the base plate 14. In this respect, a bypass channel 68''' is formed in the flow barrier 89 such that a fluid connection between the first flow passage area 24(1) and the second flow passage area 24(2) is established at a location further upstream (i.e., closer to the first end 34 of the base plate 14) than the U-reversal areas 26. Accordingly, fluid moving through the inlet manifold 54a of the first flow passage area 24(1) located on the inlet side can be directly diverted to the outlet manifold 54b of the second flow passage area 24(2) located on the outlet side by means of the bypass channel 68''' without completing its full passage through the heat exchanger 10.In the present embodiment, the bypass channel 68''' is located at the first end 34 of the base plate between the circumferential flange 22 and the first end 37 of the dividing rib 28(3), which defines the flow barrier 89.

[0057] In addition to or instead of providing the bypass channel 68''' at the first end 37 of the dividing rib 28(3), one or more other ribs 28(1), 28(2) and / or one or more of the transverse rib sections 90, which define flow passages 24a, 24b, 24c, 24d, may be interrupted at any point along their length to provide additional bypass channels 68. The possible locations for these additional bypass channels are shown in Fig. 16 is indicated by reference numeral 68x.

[0058] Another feature of the base plate 14 of the heat exchanger 10" is the provision of a bypass rib area 94 located in the bypass channel 68''' to adjust and guide the bypass flow of cooling fluid between the openings 30, 32, and / or to provide structural support within the inlet manifold space 54a.

[0059] Therefore, while various embodiments of battery cooling heat exchangers with integrated bypass features have been described, it should be noted that certain adaptations and modifications of the described embodiments are possible. The embodiments discussed above should therefore be considered illustrative and not limiting.

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