A heat exchanger

Abstract

A heat exchanger system (100) includes a base plate (10), a channel plate (20) abutting the base plate (10), an inlet nozzle (24) and an outlet nozzle (26) The channel plate (20) includes first channels protruding in a first direction defining first fluid flow passages between the base plate and the channel plate. The inlet nozzle (24) and the outlet nozzle (26) allow for ingress and egress of fluid respectively into the heat exchanger (100) through the first channels (22). A portion of the base plate (10) comprises one or more second channels (12) protruding in a second direction opposite to the first direction. The second channels (12) define second fluid flow passages between the base plate (10) and the channel plate (20) for configuring fluid communication between at least one first channel (22) and the outlet nozzle (26).

Description

[0001] TITLE

[0002] A HEAT EXCHANGER

[0003] TECHNICAL FIELD

[0004] The present invention relates to heat exchanger, more specifically, a cooling plate for a battery pack of an electric or a hybrid vehicle.

[0005] BACKGROUND OF THE INVENTION

[0006] Vehicle electrification is a conscious step that automakers are taking towards a sustainable future. Conventional fuel vehicles such as petrol and diesel vehicles have advantage with respect to driving range, and there is constant consumer demand to increase the range of electric vehicles. To catch up with this demand, auto-manufacturers are opting for bigger, more powerful battery packs with higher energy densities.

[0007] Such battery packs generate heat due a variety of reasons such as internal resistance, enthalpy changes, etc. as they charge or discharge. Elevated temperatures due to the heating of the battery cells can adversely impact battery health and in worse cases may lead to thermal runaway. As a result, it is very important to effectively dissipate the heat generated during the operation of the battery.

[0008] Electric vehicles utilize a heat-exchanger, particularly, a battery cooler for heat dissipation from the battery pack to cool the battery pack. The battery cooler can be deployed either underneath the battery pack or on top it.

[0009] The battery cooler may be disposed on top of a casing receiving the battery pack, such as for example, a vehicle traction battery pack. The battery cooler acts as a cover to protect the battery pack against adverse environmental conditions and can be removed to access to the battery pack for service and maintenance.

[0010] The battery cooler comprises a base plate that faces the battery pack and a channel plate that faces away from the battery pack. For better contact and to provide effective heat transfer area with the battery modules, the base plate is formed flat. The channel plate comprises stamped channels formed thereon that are closed by the abutting base plate when the base plate is assembled to the channel plate, to create closed channels allowing coolant flow through them.

[0011] The coolant fluid enters the battery cooler through an inlet nozzle. The coolant fluid exits the battery cooler through an outlet nozzle after undergoing heat exchange while passing through the closed channels. More specifically, the inlet nozzle is in fluid communication with the closed channels in the battery cooler through which the coolant flows and undergoes heat exchange to absorb heat from the heat generating components, such as a battery pack of an electric vehicle, in contact with the base plate. Finally, the coolant exits the through the outlet nozzle in fluid communication with the closed channel(s). More particularly, the coolant flows through distribution channels that bifurcate into narrower channels, known as functional channels. The functional channels are spread over a substantial portion of the channel plate to define fluid flow passages for heat exchange. The functional channels finally merge in to collection channels of comparatively larger cross section than the functional channels and are arranged along the peripheries of the channel plate. The collection channels, eventually, are in fluid communication with the outlet nozzle through which the coolant egresses the battery cooler.

[0012] Since the multiple functional channels are in fluid communication with comparatively fewer collection channels, there is a build-up of backpressure in the collection channels, particularly, at terminal ends of the collection channels. The back-pressure in the collection channels results in pressure drop across the functional channels and efficiency and performance of the battery cooler is reduced. Further, any structural changes in the channels to address the back pressure issue are restricted by packaging constraints and serviceability considerations of the inlet and outlet nozzles, as the channels interfere with the inlet and outlet nozzles.

[0013] OBJECT OF THE INVENTION

[0014] An object of the invention is to improve the clearance between the inlet nozzle and the collection channels to improve serviceability of the battery cooler avoiding any interference between the inlet connector and the collection channels while the inlet connector is being dis- assembled / assembled for servicing purposes.

[0015] Yet another objective of the invention is to reduce backpressure in the fluid flow in the region where the collection channels merge.

[0016] SUMMARY OF THE INVENTION

[0017] The present invention relates to a heat exchanger system that includes a base plate, a channel plate, an inlet nozzle and an outlet nozzle. The base plate is adapted to be in contact with a heat generating component, such as a battery pack in an electric or a hybrid vehicle. The channel plate is disposed abutting the base plate. The channel plate includes a plurality of first channels protruding in a first direction. The first channels are adapted to define first fluid flow passages between the base plate and the channel plate. The at least one inlet nozzle and at least one outlet nozzle allow for ingress and egress of fluid respectively with respect to the first channels. The inlet nozzle is in fluid communication with at least one of the first channels to distribute fluid thereto and the outlet nozzle is in fluid communication with at least one of the first channels to collect fluid therefrom. At least a portion of the base plate comprises one or more second channels protruding in a second direction opposite to the first direction. The second channels define second fluid flow passages between the base plate and the channel plate for configuring fluid communication between at least one of the first channels and the outlet nozzle.

[0018] Generally, the one or more second channels are adapted to configure fluid communication between two terminal ends of one or more of the first channels and the at least one outlet nozzle.

[0019] Particularly, at least one of the first channels is in fluid communication with at least one outlet nozzle via at least one, second channel.

[0020] Specifically, the second channels comprise at least one straight channel.

[0021] More specifically, the second channels comprise at least one curved channel.

[0022] Generally, the second channels comprise at least one straight channel and at least one curved channel.

[0023] Further the one or more second channels have uniform cross sectional area.

[0024] Particularly, the second channels have a combined cross sectional area which is equal to or greater than the combined cross sectional area of the one or more first channels in fluid communication with the second channels.

[0025] Generally, the second channels are spaced away from a joining edge between the base plate and the channel plate. Specifically, the heat exchanger also acts as a cover of the heat generating component, such as a top cover of a battery pack in an electric or a hybrid vehicle.

[0026] BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Other characteristics, details and advantages of the invention may be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

[0028] FIG. 1 illustrates a schematic representation depicting an arrangement of a heat exchanger and a heat generating component, such as for example a battery pack.

[0029] FIG. 2 illustrates an exploded view depicting elements of the heat exchanger of FIG. 1 , including a base plate and a channel plate.

[0030] FIG. 3A illustrates a top view of the heat exchanger of FIG. 1 depicting constructional details of the channel plate formed with multiple channels.

[0031] FIG. 3B illustrates the sectional view of an inlet nozzle, the base plate and the channel plate of the heat exchanger of FIG. 1 along a section line AA depicted in FIG. 3A.

[0032] FIG. 4 illustrates an enlarged isometric view of the inlet nozzle and an outlet nozzle of the heat exchanger of FIG. 1 FIG. 5A illustrates the top view of the base plate of the heat exchanger of FIG. 1 in isolation. Also depicted is an enlarged view depicting portion of the base plate formed with second channels.

[0033] FIG. 5B illustrates the sectional view of the base plate of the heat exchanger of FIG. 1 along a section line BB depicted in FIG. 5A.

[0034] FIG. 6A illustrates another isometric view of the heat exchanger of FIG.1 depicting the base plate and the channel plate in assembled configuration.

[0035] FIG. 6B illustrates a sectional view of the heat exchanger along the section line CC depicted in FIG 6A.

[0036] DETAILED DESCRIPTION

[0037] It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0038] The present invention envisages a battery cooler for cooling a vehicle battery to overcome the challenges faced by conventional battery coolers wherein fluid flow channels of a channel plate protruding from the battery cooler cause servicing difficulties, more specifically, these channels interfere with the cooling fluid connectors while disconnecting the in let / outlet cooling fluid connectors. In the present invention, the battery cooler involves additional channels strategically arranged on a base plate and protruding in an opposite direction providing better clearance for disconnecting the inlet / outlet cooling fluid connectors and to prevent back pressure issues in the fluid flow channels. The present invention is applicable to any heat exchanger system used in automotive or non-automotive applications that is required to be simple in construction, compact and that requires ease of serviceability and disconnection of coolant inlet and outlet connectors.

[0039] FIG. 1 illustrates an isometric view of a heat exchanger 100 in an assembled configuration along with a battery pack 200 in accordance with an embodiment of the present invention.

[0040] In accordance with an embodiment of the present invention, the heat exchanger 100 is placed on top of a heat-generating component 200, such as a battery of an electric or a hybrid vehicle, as a top cover for protecting the battery from various environmental dust, debris or other damages.

[0041] Without limitation, the heat exchanger 100 may be placed on the bottom or on any of the sides of the heat-generating component 200, such as the battery of the electric or hybrid vehicle.

[0042] FIG. 2 illustrates an exploded view of the heat exchanger 100 depicting placement and interaction between various elements thereof, in accordance with an embodiment of the present invention. The figure depicts a base plate 10 disposed abutting a channel plate 20 of the heat exchanger 100. The base plate 10 is assembled to the channel plate 20 to configure channels. The channel plate 20 includes a plurality of first channels 22 that protrude in a first direction. The plurality of first channels 22 of the channel plate 20 and the base plate 10 define a plurality of first fluid flow passages allowing a cooling fluid to flow therein.

[0043] According to an embodiment, an inlet nozzle 24 and an outlet nozzle 26 are functionally connected to the channel plate 20. The inlet nozzle 24 is configured for ingress of cooling fluid into the heat exchanger 100 and the outlet nozzle 26 is configured for egress of the cooling fluid from the heat exchanger 100.

[0044] Further, the base plate 10 comprises at least one second channel 12 protruding in a second direction that is substantially opposite to the first direction. In one embodiment, if the first channels 22 extend in the + Z direction, then the second channels 12 extend in the - Z direction. The second channels 12 and the channel plate 20 define a plurality of fluid flow passages allowing the cooling fluid to flow through it. Further, the second channels 12 configure fluid communication between at least one of the first channels 22 and the outlet nozzle 26.

[0045] FIG. 3A illustrates a top view of the heat exchanger 100, particularly, channel plate 20 side of the heat exchanger 100. The first channels 22 of the channel plate 20 includes one or more distribution channels 22a. The cooling fluid enters into the heat exchanger 100 through the inlet nozzle 24 and then flows through one or more distribution channels 22a. Each of the distribution channels 22a subdivide into a plurality of functional channels 22b. The functional channels 22b are distributed over a substantial area of the heat exchanger 100 and are primarily responsible for carrying out the heat transfer process. The functional channels 22b merge into one or more collection channels 22c. The one or more collection channels 22c terminate at one or more terminal ends 28.

[0046] In an embodiment, the functional channels 22b merge into two collection channels 22c disposed along laterally opposite sides of the heat exchanger 100 and terminate at two terminal ends 28 in proximity of the inlet nozzle 24. The outlet nozzle 26 is positioned at one of the terminal ends 28. The channel plate 20 is substantially devoid of first channels 22 in a region 29 in the proximity of the inlet nozzle 24. This allows clearance for the inlet nozzle 24 during its detachment for servicing purposes. Without limitation, it should be appreciated that the channel plate 20 may have any number of collection channels 22c without departing from the scope of the invention.

[0047] FIG. 3B illustrates the sectional view of the inlet nozzle, the base plate and the channel plate of the heat exchanger of FIG. 1 along a section line AA depicted in FIG. 3A. The section AA passes through the region 29 (shown in FIG. 3A). Since there are only the second channels 12 extending in the -Z direction (shown in FIG. 2) and there are no channels on the channel plate 20 in the region 29 in +Z direction (shown in FIG. 2), there is a clearance ‘c’ in Z direction between the channel plate and the bottom edge of the inlet nozzle 24. This allows clearance for detachment of the inlet nozzle 24 for servicing purposes.

[0048] FIG. 4 illustrates an isolated enlarged view of the inlet nozzle 24 and the outlet nozzle 26. The inlet nozzle 24 comprises an inlet sleeve 242 attached to the distribution channels 22a. An inlet plastic receiver 244 abuts the inlet sleeve 242 and is attached using a suitable fastening means, such as a screw, bolt or the like. A detachable inlet connector 246 connects detachably with the inlet plastic receiver 244 and can be detached easily when necessary, such as during servicing. In an embodiment the detachable inlet connector 246 may be a quick-connect fluid coupling type connector. The outlet nozzle 26 comprises an outlet sleeve 262 attached to the terminal end 28 of the collection channel 22c. An outlet plastic receiver 264 abuts the outlet sleeve 262 and is attached using a suitable fastening means, such as a screw, bolt or the like. A detachable outlet connector 266 connects detachably with the outlet plastic receiver 264 such as a quickconnect fluid coupling type connector.

[0049] During servicing of the heat exchanger 100 an operator has to detach the quick-connect detachable inlet connector 246 from the inlet plastic receiver 244. Similarly, the operator may also need to detach the inlet plastic receiver 244 from the inlet sleeve 242 by opening the fastening means, such as a screw, bolt or the like. This necessitates adequate clearance for tooling to detach the inlet nozzle of parts thereof. As stated earlier, the channel plate 20 devoid of any first channels 22 in a region 29 in the proximity of the inlet nozzle 24. This creates more clearance for the inlet nozzle 24 that aids during servicing. However, since the coolant fluid in the first channels 22 (more specifically collection channel 22c) that needs to be conveyed to the outlet nozzle 26 is hence bypassed through the second channels 12 that protrude in the opposite direction as that of the first channels 12.

[0050] FIG. 5A illustrates a top view of the base plate 10 and an enlarged view of the second channel 12. The second channel 12 comprises a first terminal end 12c and a second terminal end 12d. In a preferred embodiment, the second channels 12 may comprise two channels 12a and 12b that have common terminal points 12c and 12d.

[0051] FIG. 5B illustrates a sectional view of the base plate 10 about an axis BB (shown in FIG. 5A) depicting the sectional profile of the second channels 12a and 12b and one of the terminal points 12d.

[0052] In an embodiment, each of the one or more second channels 12 have uniform cross sectional area. Further, the combined cross sectional area of the one or more second channels 12, is equal to or greater than the combined cross sectional area of the one or more first channels 22 that are in fluid communication with the second channels. In other words, the combined cross sectional area of the second channels 12a and 12b is equal to or greater than the combined cross sectional area of the collection channels 22c. This ensures that there is no fluid back pressure accumulation when coolant fluid bends and transitions between the collection channel 22c of the channel plate and the second channels 12 of the base plate 10 at the terminal ends 12c, 12d.

[0053] FIG. 6A is an isometric view of the base plate 10 and the channel plate 20 joined together. The base plate 10 and the channel plate 20 are joined together at a joining edge 30 using a suitable connection such as crimping, hemming, brazing, welding, or the like. The first channels 10 and the second channels 12 are spaced away from a joining edge 30 so as to preserve the structural integrity of the heat exchanger 100.

[0054] FIG. 6B illustrates a sectional view of the joined base plate 10 and the channel plate 20 along a section CC (of FIG. 6A). The figure shows that the terminal points 12c and 12d of the second channels 12 are substantially aligned with the terminal points 28 of the collection channels 22c. Further, the first channels 22 (more specifically the collection channels 22c) are connected to each other by the second channels 12a and 12b (not visible in this figure).

[0055] In an embodiment of the present invention, the second channels 12 allow fluid communication between the terminal ends 28 of the one or more of the first channels 22 and the outlet nozzle 26.

[0056] In another embodiment, the first channels 22, and more specifically the collection channel 22c is in fluid communication with at least one outlet nozzle via at least one second channels 12.

[0057] In one embodiment, the second channels 12 comprise at least one straight channel 12a.

[0058] In another embodiment, the second channels 12 comprise at least one curved channel 12b.

[0059] In yet another embodiment, the second channels 12 comprise at least one straight channel 12a and at least one curved channel 12b.

Claims

CLAIMS1 . A heat exchanger (100) comprising:• a base plate (10) adapted to be in contact with a heat generating component (200), such as a battery pack in an electric or a hybrid vehicle,• a channel plate (20) disposed abutting the base plate (10), said channel plate (20) comprising first channels (22) protruding in a first direction, the first channels (22) being adapted to define first fluid flow passages between the base plate (10) and the channel plate (20),• at least one inlet nozzle (24) and at least one outlet nozzle (26) for ingress and egress of fluid respectively with respect to the first channels (22), the inlet nozzle (24) being in fluid communication with at least one of the first channels (22) to distribute fluid thereto and the outlet nozzle (26) being in fluid communication with at least one of the first channels (22) to collect fluid therefrom, characterized in that, at least a portion of the base plate (10) comprises one or more second channels (12) protruding in a second direction opposite to the first direction, the second channels (12) being adapted to define second fluid flow passages between the base plate (10) and the channel plate (20) for configuring fluid communication between at least one of the first channels (22) and the outlet nozzle (26).

2. The heat exchanger (100) as claimed in claim 1 , wherein the one or more second channels (12) are adapted to configure fluid communication betweenone or more terminal ends (28) of the one or more of the first channels (22) and the at least one outlet nozzle (26).

3. The heat exchanger (100) as claimed in claim 1 , wherein at least one of the first channels (22) is in fluid communication with at least one outlet nozzle (26) via at least one second channel (12).

4. The heat exchanger (100) as claimed in claim 3, wherein the second channels (12) comprise at least one straight channel (12a).

5. The heat exchanger (100) as claimed in claim 3, wherein the second channels (12) comprise at least one curved channel (12b).

6. The heat exchanger (100) as claimed in claim 3, wherein the second channels (12) comprise at least one straight channel (12a) and at least one curved channel (12b).

7. The heat exchanger (100) as claimed in any of the preceding claims, wherein the each of the one or more second channels (12) have uniform cross sectional area.

8. The heat exchanger (100) as claimed in claim 7, wherein the second channels (12) have a combined cross sectional area which is equal to or greater than the combined cross sectional area of the one or more first channels (22) in fluid communication with the second channels (12).

9. The heat exchanger (100) as claimed in the claim 1 wherein, the first channels (10) and the second channels (12) are spaced away from a joining edge (30) between the base plate (10) and the channel plate (20).

10. The heat exchanger (100) as claimed in any of the preceding claims, wherein the heat exchanger (100) also acts as a cover of the heat generating component (200), such as a top cover of a battery pack in an electric or a hybrid vehicle.

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