Single-phase to two-phase fluid heat exchangers and systems thereof

Abstract

The various embodiments described herein include devices and systems for a heat exchanger. The heat exchanger includes a housing including a predetermined number of channels, and a predetermined number of baffles. The predetermined number of channels are disposed along a first direction within the housing and each baffle is disposed at distinct portion within the housing along a second direction. The heat exchanger includes a first fluid inlet and a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels. The heat exchanger includes a second fluid inlet and a second fluid outlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing. The second flow of the single-phase fluid being guided through the housing based on the predetermined number of baffles.

Description

004210-5029-WQSINGLE-PHASE TO TWO-PHASE FLUID HEAT EXCHANGERS AND SYSTEMS THEREOF CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No.63 / 769,418, filed March 10, 2025, entitled "SINGLE-PHASE TO TWO-PHASE FLUID HEAT EXCHANGERS AND SYSTEMS THEREOF," the entire contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] The present disclosure relates to refrigeration systems and components thereof, and more particularly to single-phase to two-phase fluid heat exchangers for thermal management systems and heating, ventilation, and air-conditioning systems.BACKGROUND

[0003] Existing heat exchangers, such as brazed plate heat exchangers, have several limitations that can make them difficult to use. For example, brazed plate heat exchangers can be limited to specific pressure and temperature ranges. If a system designed to operate within the pressure and temperature ranges of a brazed plate heat exchanger, the system will operate inefficiently or fail to provide reliable heat transfer. Additionally, brazed plate heat exchangers can result in higher pressure drops which make systems inefficient. In some cases, brazed plate heat exchangers can leak or clog further reducing efficient or the ability to provide reliable heat transfer. Additionally, non-uniform temperature distribution that is inherent to brazed plate heat exchangers creates maldistribution causing the two phase fluid to evaporate or condense and non-uniformly reducing the available heat transfer area, therefore reducing the brazed plate heat exchangers capacity and causing oil trapping.

[0004] As such, there is a need for heat exchangers that provide improved efficiency and are easy to manufacture.SUMMARY

[0005] The devices and system described herein provide an improved heat exchanger that increases heat transfer efficiency. The devices and system described herein provide singlephase to two-phase fluid heat exchangers that reduce a pressure drop of a single-phase fluid004210-5029-WQand enhance the distribution of a single-phase fluid and a two-phase fluid within the heat exchangers (e.g., providing consistent and / or evenly distributed two-phase fluid flow and single-phase fluid flow within the heat exchangers). In some embodiments, the devices and system described herein utilize micro-channel technology for improving the two-phase fluid flow, thereby improving refrigerant distribution, improving oil return, and reducing pressure drop. As described below, the disclosed heat exchangers can be used in different thermal management systems, such as a heating, ventilation, and air conditioning (HVAC) systems and battery and electronics cooling and heating systems.

[0006] In one aspect, a heat exchanger is disclosed. The heat exchanger includes a housing. The housing includes a predetermined number of channels disposed along a first direction within the housing, and a predetermined number of baffles. Each baffle of the predetermined number of baffles is disposed at a distinct portion within the housing along a second direction, perpendicular to the first direction. The heat exchanger includes a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels and a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels. The heat exchanger further includes a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing and a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing. The second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles.

[0007] In another aspect, a thermal management system is disclosed. The thermal management system includes a compressor; a first heat exchanger fluidically coupled to the compressor; an expansion device fluidically coupled to the first heat exchanger; and a second heat exchanger fluidically coupled to the expansion device and the compressor. The first heat exchanger and / or the second heat exchanger are heat exchangers including a housing, a predetermined number of channels disposed along a first direction within the housing, and a predetermined number of baffles. Each baffle of the predetermined number of baffles is disposed at distinct portion within the housing along a second direction, perpendicular to the first direction. The heat exchanger includes a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels and a first fluid outlet fluidically coupled to the004210-5029-WQpredetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels. The heat exchanger further includes a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing and a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing. The second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles. A two-phase fluid flows through a refrigeration loop of the thermal management system, and a single-phase fluid flows through a single-phase fluid loop fluidically coupled with a heat exchanger.

[0008] In yet another aspect, a non-transitory, computer-readable storage medium including instructions executed by one or more processors of a thermal management system. The thermal management system includes a compressor; a first heat exchanger fluidically coupled to the compressor; an expansion device fluidically coupled to the first heat exchanger; and a second heat exchanger fluidically coupled to the expansion device and the compressor. The first heat exchanger and / or the second heat exchanger are heat exchangers including a housing, a predetermined number of channels disposed along a first direction within the housing, and a predetermined number of baffles. Each baffle of the predetermined number of baffles is disposed at distinct portion within the housing along a second direction, perpendicular to the first direction. The heat exchanger includes a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels and a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels. The heat exchanger further includes a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing and a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing. The second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles. A two-phase fluid flows through a refrigeration loop of the thermal management system, and a single-phase fluid flows through a single-phase fluid loop fluidically coupled with a heat exchanger.

[0009] The features and advantages described in the specification are not necessarily all inclusive and, in particular, certain additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it004210-5029-WQshould be noted that the language used in the specification has been principally selected for readability and instructional purposes.

[0010] Having summarized the above example aspects, a brief description of the drawings will now be presented.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a better understanding of the various described embodiments, reference should be made to the Detailed Description below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.

[0012] Figures 1 A-1D illustrate a heat exchanger heat exchanger, in accordance with some embodiments.

[0013] Figures 2A and 2B illustrate an example single-phase to two-phase fluid heat exchanger, in accordance with some embodiments.

[0014] Figures 3 A-3C illustrate example thermal management systems including a singlephase to two-phase fluid heat exchanger, in accordance with some embodiments.

[0015] Figure 4 is a block diagram illustrating controller, in accordance with some embodiments.

[0016] Figures 5A-5D illustrate a straight-design heat exchanger, in accordance with some embodiments.

[0017] Figures 6A-6E illustrate a U-shaped design heat exchanger, in accordance with some embodiments.DETAILED DESCRIPTION

[0018] Reference will now be made in detail to implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described implementations. However, it will be apparent to one of ordinary skill in the art that the various described implementations may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the implementations.

[0019] Many modifications and variations of this disclosure can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. The specific004210-5029-WQimplementations described herein are offered by way of example only, and the disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0020] As used herein, a “refrigerant” is a fluid adapted to undergo phase transitions between liquid and gas during operation of a corresponding refrigerant system. For example, the refrigerant has a liquid-to-gas transition point below a target operating temperature of the refrigerant system. In various implementations, the refrigerant may be a class 1, class 2, or class 3 refrigerant.

[0021] Implementations of the present disclosure are described in the context of thermal management systems, and in particular, single-phase to two-phase fluid heat exchangers that can be used in heating, ventilation, and air conditioning (HVAC) systems. While the primary examples describe thermal management systems, electronics and battery cooling and heating systems, the single-phase to two-phase fluid heat exchangers described herein can be used in different applications including but not limited to industrial processes, refrigeration, renewable energy, food and beverage processing, electronics cooling, etc. The disclosed thermal management systems are configured to thermally treat and / or condition enclosed spaces, such as vehicle (e.g., cars, trucks, aircraft, etc.) cabins, rooms, buildings, etc. Additionally, the disclosed thermal management systems can be configured to thermally treat electronics, such as batteries, processors, computers, etc.

[0022] In some embodiments, the heat exchanger design described herein is configured for coolant-to-refrigerant heat exchange applications. The heat exchanger may be configured for use with lower pressure refrigerants, such as R134a, R1234yf, and R290, as well as higher pressure refrigerants such as R744 (CO2). The heat exchanger may function as a chiller (evaporator) for cooling the coolant (e.g., the single-phase fluid) or as a coolant heater (condenser) for heating the coolant. In some embodiments, the heat exchanger is configured for battery thermal management, including battery cooling and battery heating. In this way, the heat exchanger provides versatile thermal management capabilities for various applications including vehicle thermal management, battery cooling and heating, and HVAC systems.

[0023] In some embodiments, the housing may be formed of a plastic material or a metal material (e.g., aluminum, brazed sheet metal). In embodiments where the housing is formed of plastic, the predetermined number of baffles may be integrally formed with the housing (e.g., molded into the plastic housing). In embodiments where the housing is formed of metal, the004210-5029-WQpredetermined number of baffles may be separately attached to the housing (e.g., brazed onto an interior surface of the metal housing).

[0024] In the disclosed heat exchanger, the single-phase fluid (e.g., coolant) fills or generally fills the housing such that the predetermined number of channels are submerged in the single-phase fluid. The baffles guide the single-phase fluid to flow perpendicular to the channels, creating a cross-flow or cross-counter-flow configuration. This configuration is distinct from heat exchangers where coolant flows through separate fin structures (such as offset strip fins) that are interleaved with refrigerant tubes. In the disclosed configuration, the single-phase fluid directly contacts the exterior surfaces of the channels as it flows over and between the channels, providing improved heat transfer efficiency. The disclosed configuration also reduces pressure drop of the single-phase fluid compared to configurations using offset strip fins or other flow restriction elements within the coolant flow path.

[0025] Figures 1 A-1D illustrate a heat exchanger, in accordance with some embodiments. In Figure 1 A, a perspective view of the heat exchanger 100 is shown. The heat exchanger 100 includes a housing 105. In some embodiments, the housing 105 is formed of brazed sheet metal. In some embodiments, the housing 105 is formed of plastic. The housing 105 includes a predetermined number of channels 110 and a predetermined number of baffles 115. In some embodiments, the predetermined number of baffles 115 are brazed onto an interior surface of the housing 105. In some embodiments, the predetermined number of baffles 115 are integrally formed with the housing 105 (e.g., molded into a plastic housing). In some embodiments, the heat exchanger 100 further includes a first insulator between the housing 105 and the predetermined number of channels 110 and a second insulator between the predetermined number of baffles 115 and the predetermined number of channels 110. The heat exchanger 100 further includes a first fluid inlet (represented by inlet first flow arrow 130), a first fluid outlet (represented by outlet first flow arrow 135), a second fluid inlet (represented by inlet second flow arrow 120), and a second fluid outlet (represented by outlet second flow arrow 125).

[0026] The predetermined number of channels 110 are disposed along a first direction (e.g., the x-axis) within the housing 105. In some embodiments, the predetermined number of channels 110, a subset of the predetermined number of channels 110, and / or portions of the predetermined number of channels 110 are meandering such that at least two channels or portions of two channels of the predetermined number of channels 110 are disposed along the first direction within the housing 105 at distinct planes along a third direction (e.g., at distinct004210-5029-WQheights of the housing 105 or along the z-axis). In some embodiments, the distinct planes along the third direction are separated by a predetermined gap (e.g., 1 mm, 5 mm, 10 mm, etc.). In other words, in some embodiments, there is a predetermined gap or space between adjacent channels of the predetermined number of channels 110. In some embodiments, the predetermined gap between channels is the same or distinct.

[0027] The predetermined number of baffles 115 are disposed at distinct portion within the housing 105 along a second direction (e.g., the y-axis), perpendicular to the first direction, and extend all or substantially all of the height of the housing 105 (e.g., along a third direction or the z-axis). For example, as shown in Figure 1 A, each baffle (e.g., 115a, 115b, and 115c) of the predetermined number of baffles 115 is disposed at distinct portion within the housing 105 extends towards a center portion of the housing 105 (e.g., in the second direction), perpendicular to the predetermined number of channels 110, and extends from the bottom to the top of the housing 105 (e.g., in the third direction). In some embodiments, the predetermined number of baffles 115 extend in the second direction a predetermined distance. In some embodiments, the predetermined distance is such that each baffle of the predetermined number of baffles 115 contacts or approximately contacts a respective edge of the predetermined number of channels 110. For example, as shown in Figure 1 A, the predetermined number of baffles 115 extend towards the center of the housing 105 and contact or approximately contact the predetermined number of channels 110. Alternatively, or in addition, in some embodiments, the predetermined number of baffles 115 include one or more shaped edges (e.g., square edges, circular edges, etc.), each shaped edge being configured to fit within a respective predetermined gap of the predetermined number of channels 110 such that the predetermined number of baffles 115 can extend further in the second direction (e.g., partially within or past the predetermined number of channels 110).

[0028] The first fluid inlet and the first fluid outlet are fluidically coupled to the predetermined number of channels 110. The first fluid inlet and the first fluid outlet facilitate a first flow of a first fluid through the predetermined number of channels 110. The first fluid inlet and the first fluid outlet can be fluidically coupled to a thermal management system (e.g., any thermal management system described below in reference to Figures 3A-3C). The first fluid inlet receives the first flow of the first fluid via a fluidically coupled thermal management system and the first fluid outlet returns the first flow of the first fluid to the fluidically coupled thermal management system. In other words, the first fluid inlet and the first fluid outlet are fluidically coupled to a first fluid loop of an thermal management system. In some004210-5029-WQembodiments, the first fluid loop of an thermal management system is a refrigeration loop. In some embodiments, the first fluid is a single-phase fluid (e.g., a fluid that remains in a single phase (e.g., liquid, gas, etc.) during a (heating or cooling) process)). In some embodiments, the single-phase fluid is oil, alcohol, water, other coolants, and / or other substances. For example, the single-phase fluid can be glycol. In some embodiments, the first fluid is a two-phase fluid (e.g., a fluid that undergoes a phase change (e.g., liquid-gas, gas-solid, liquid-solid, and / or any combination thereof) during a (heating or cooling) process). In some embodiments, the two-phase fluid is a refrigerant.

[0029] The second fluid inlet and the second fluid outlet are fluidically coupled to the housing 105. The second fluid inlet and the second fluid outlet facilitate a second flow of a second fluid through the housing 105. The second fluid is configured to be received within the housing 105 and substantially fill the housing 105 such that the predetermined number of channels 110 and the predetermined number of baffles 115 are fully or substantially submerged in the second fluid. As discussed in detail below in reference to Figure IB, the predetermined number of baffles 115 guide the second flow of the second fluid within the housing 105 and towards the second fluid outlet. The second fluid inlet and the second fluid outlet are fluidically coupled to a thermal management system (e.g., any thermal management system described below in reference to Figures 3A-3C). In some embodiments, the second fluid inlet receives the second flow of the second fluid via a fluidically coupled thermal management system and the second fluid outlet returns the second flow of the second fluid to the fluidically coupled thermal management system. In other words, the second fluid inlet and the second fluid outlet are fluidically coupled to a second fluid loop of a thermal management system. In some embodiments, the second fluid loop of a thermal management system is a liquid loop. Alternatively, or in addition, in some embodiments, the second fluid inlet is fluidically coupled to a ventilation inlet (not shown) such that ventilated air is combined with the second fluid or the second fluid is ventilated air, and the second fluid outlet is fluidically coupled to an exhaust (not shown) such that the second fluid could be removed from a second fluid loop or returned to the second fluid loop. In some embodiments, the second fluid is a single-phase fluid. In some embodiments, the second fluid is a liquid.

[0030] The predetermined number of channels 110 and the predetermined number of baffles 115 are selected such that a first flow of a first fluid through the predetermined number of channels 110 passes over a second flow of a second fluid through the housing 105 at least once. In some embodiments, the predetermined number of channels 110 and the004210-5029-WQpredetermined number of baffles 115 are selected such that the first flow of the first fluid through the predetermined number of channels passes 110 over the second flow of the second fluid through the housing 105 at least twice. In some embodiments, the predetermined number of channels and the predetermined number of baffles are selected such that there is a predetermined ratio of passes (e.g., 1 pass of the first fluid to 1 pass of the second fluid, 2 passes of the first fluid to 1 pass of the second fluid, etc.).

[0031] In some embodiments, the heat exchanger 100 is configured to operate as an evaporator or a condenser of a thermal management system. In some embodiments, the heat exchanger 100 is configured for coolant-to-refrigerant heat exchange and may operate as a water chiller (evaporator) to cool a coolant (e.g., the single-phase fluid) or as a water gas cooler or coolant heater (condenser) to heat the coolant. In some embodiments, the heat exchanger 100 is configured for use with lower pressure refrigerants, such as R134a, R1234yf, and R290, as well as higher pressure refrigerants such as R744 (CO2). In some embodiments, the heat exchanger 100 is configured for battery thermal management, including battery cooling during normal operation or fast charging, and battery heating during cold weather conditions. Depending on the operation of the heat exchanger 100 (e.g., condenser or evaporator), the predetermined number of channels 110, an orientation of the predetermined number of channels 110 (e.g., disposed along an x-axis, y-axis, and / or z-axis), the predetermined number of baffles 115, an orientation of the predetermined number of baffles 115 (e.g., disposed along an x-axis, y-axis, and / or z-axis), the orientation of the housing 104, and / or a configuration of the housing 105 (e.g., square housing, circular housing, tubular housing, size of the housing, etc.) can be adjusted.

[0032] Figure IB shows a top view of the heat exchanger 100, which provides a visual representation of the first flow of the first fluid entering the predetermined number of channels 110, via the first fluid inlet (represented by inlet first flow arrow 130), and leaving the predetermined number of channels 110, via the first fluid outlet (represented by outlet first flow arrow 135); and a visual representation of the second flow of the second fluid entering the housing 105, via the second fluid inlet (represented by inlet second flow arrow 120), being redirected by the predetermined number of baffles 115, and leaving the housing 105, via the second fluid outlet (represented by outlet second flow arrow 125). As will be apparent to those skilled in the art, the visual representations of the flow shown in Figure IB are provided for discussion and do not fully represent the flow within the heat exchanger 100.004210-5029-WQ

[0033] The first fluid (represented by the pattern filled arrows) enters via the first fluid inlet and flows along the first direction (e.g., along an x-axis) toward the first fluid outlet. The first fluid flows through each channel of the predetermined number of channels 110, which are disposed along the first direction within the housing 105. As described above, in some embodiments, the predetermined number of channels 110, a subset of the predetermined number of channels 110, and / or portions of the predetermined number of channels 110 are meandering. The meandering configuration of the predetermined number of channels 110 allows the first fluid can traverse the first direction a predetermined number of times (e.g., based on the number of the predetermined number of channels 110). For example, at least two channels allows the first fluid to traverse the first direction at least twice.

[0034] The second fluid (represented by the unfilled arrows) enters via the second fluid inlet, flows into the housing 105, fills (or substantially fills) the housing 105, and is directed through the housing 105, via the predetermined number of baffles 115, toward the second fluid outlet. The predetermined number of baffles 115 cause the second fluid to flow perpendicularly across the predetermined number of channels 110 (and the flow of the first fluid). For example, as shown in Figure IB, the first fluid flows substantially in the first direction (e.g., the x-axis) and the second fluid flows substantially in the second direction (e.g., the y-axis) over the predetermined number of channels 110 (and / or through the predetermined gaps between channels of the predetermined number of channels 110). Because the second fluid substantially fills or fills the housing 105, the second fluid flows in the second direction along the third direction (e.g., the height of the housing 105 or the z-axis). When the second fluid flows over the predetermined number of channels 110 (and / or through the predetermined gaps between channels of the predetermined number of channels 110), heat is transferred between the first fluid flowing with the predetermined number of channels 110 and the second fluid flowing within the housing 105.

[0035] While only three baffles (e.g., 115a-l 15c) are shown in Figures 1 A and IB, the heat exchanger 100 can include more or less than three baffles depending on the design and application of the heat exchanger 100.

[0036] Figure 1C shows a predetermined number of channels 110 of the heat exchanger 100. The predetermined number of channels 110 can include one or more channels (e.g., first channel 140-1 through n channel 140-n). Each channel is disposed along a first direction (e.g., the x-axis). In some embodiments, adjacent channels are separated by a predetermined gap. For example, a first channel 140-1 is separated by the second channel 140-2 by a004210-5029-WQpredetermined gap. In this way, the first channel 140-1 and the second channel 140-2 are both disposed along the first direction on distinct planes along the third direction (e.g., the z-axis).

[0037] Figure ID show a single channel of the predetermined number of channels 110. A channel of the predetermined number of channels 110 can be a microchannel tube or channel, a multiport tube or channel, a multiport micro-channel, or a tube, each of which can include a predetermined number of sub-channels. In some embodiments, the predetermined number of sub-channels is at least 1, at least 4, at least 8, at least 12, at least 24, etc. In some embodiments, a first channel 140-1 is a first microchannel tube and a second channel 140-2 is a second microchannel tube. The first and the second microchannel tubes can be the same or distinct (e.g., including the same or distinct predetermined number of sub-channels, diameters, etc.).

[0038] The heat exchanger of Figures 1 A-1D is configured to reduce a pressure drop of the single-phase fluid and the two-phase fluid within the housing 105, which improves the efficiency of the heat exchanger. Additionally, the heat exchanger of Figures 1A-1D distributes the flow of the single-phase fluid and the two-phase fluid to improve heat transfer efficiency.

[0039] Figures 2A and 2B illustrate an example single-phase to two-phase fluid heat exchanger, in accordance with some embodiments. The single-phase to two-phase fluid heat exchanger 200 is an example of heat exchanger 100 (Figures 1A-1D). The single-phase to two-phase fluid heat exchanger 200 includes a housing 205, a predetermined number of channels 210, a predetermined number of baffles 215, a two-phase fluid inlet 230, a two-phase fluid outlet 235, a single-phase fluid inlet 220, and a single-phase fluid outlet 225. The predetermined number of channels 210 and the predetermined number of baffles 215 are disposed within the housing 205 as described above in reference to Figures 1 A-1D.

[0040] Figure 2A illustrates the second fluid flowing through the housing 205. As shown in Figures 2A, the single-phase fluid (represented by the white arrows) is caused to flow over (and / or through gaps of) the predetermined number of channels 210 as the single-phase fluid travels toward the single-phase fluid outlet 225. In particular, when the single-phase fluid reaches and / or contacts a baffle (e.g., a first through third baffles 215a-215c), the flow of the single-phase fluid is redirected to be perpendicular to the predetermined number of channels 210 such that the single-phase fluid flows over (and / or through gaps of) the predetermined number of channels 210 and is substantially perpendicular to the two-phase fluid traveling through the predetermined number of channels 210.004210-5029-WQ

[0041] Figure 2B shows the two-phase fluid inlet 230, the two-phase fluid outlet 235, the single-phase fluid inlet 220, and the single-phase fluid outlet 225. The single-phase fluid inlet 220 and the single-phase fluid outlet 225 are fluidically coupled to the housing 205. The two-phase fluid inlet 230 and the two-phase fluid outlet 235 are coupled to the predetermined number of channels 210. The housing 205 forms an air-tight enclosure that is filled or substantially filled by the single-phase fluid. In some embodiments, the housing 205 is formed of sheet metal.

[0042] In some embodiments, the two-phase fluid inlet 230 and the two-phase fluid outlet 235 are fluidically coupled to a two-phase fluid loop, and the single-phase fluid inlet 220 and the single-phase fluid outlet 225 are fluidically couple to a single-phase fluid loop. In some embodiments, the two-phase fluid loop and the single-phase fluid loop are part of a thermal management system (e.g., any thermal management system described below in reference to Figures 3A-3C).

[0043] Figures 3A-3C illustrate example thermal management systems including a singlephase to two-phase fluid heat exchanger, in accordance with some embodiments. Figure 3 A shows a first example thermal management system 301. The first example thermal management system 301 includes a first loop and a second loop. The first loop can be a two-phase fluid loop (e.g., a loop including a two-phase fluid) and the second loop can be a singlephase fluid loop (e.g., a loop including a single-phase fluid). In some embodiments, the first loop (e.g., a refrigeration loop) configured to cool, heat, and / or condition enclosed spaces (e.g., vehicles (cars, trucks, aircrafts, etc.), cabins, rooms, buildings, etc.) thermally coupled with a portion of the first example thermal management system 301. Additionally, or alternatively, in some embodiments, the first loop is also configured to cool and / or heat electronics (e.g., computers, displays, processors, batteries, etc.) thermally coupled with a portion of the first example thermal management system 301. The second loop (e.g., a return air loop, a liquid loop, a ventilation channel, etc.) is fluidically coupled with at least one component of the first loop as described below. In some embodiments, the second loop is configured to cool thermally treat (heat and / or cool) one or more spaces and / or components thermally coupled with a portion of the first example thermal management system 301. The second loop is configured to improve the efficiency and performance of the first example thermal management system 301. The first example thermal management system 301 can include a controller 325 for receiving operational data from and / or controlling one or more components of the first example thermal management system 301.004210-5029-WQ

[0044] Turning to the first loop of the first example thermal management system 301, the first loop of the first example thermal management system 301 can include a compressor 305, a first heat exchanger 310 (e.g., a condenser), one or more expansion devices (e.g., a first expansion device 315 and a second expansion device 317), and a second heat exchanger 320 (e.g., an evaporator). In some embodiments, the first example thermal management system 301 includes a reversing valve 307. In some embodiments, the first loop of the first example thermal management system 301 includes one or more air movers 360 coupled or disposed adjacent to the first heat exchanger 310. The one or more air movers 360 are configured to move air in or out of the first example thermal management system 301, which can affect the efficiency of the first example thermal management system 301 (e.g., cause a change in a temperature or pressure of the two-phase fluid). In some embodiments, the first loop of the first example thermal management system 301 includes one or more sensor (e.g., a second sensor 365b) for obtaining operational data of the first example thermal management system 301. Additional sensors not shown can be positioned along different portions of the first loop.

[0045] The compressor 305 can be any type of compressor including but not limited to a reciprocating compressor, rotary compressor, scrolling compressor, centrifugal compressor, screw compressor, etc. The compressor 305 is configured to cause a two-phase fluid to move through the first loop at different flow rates. The compressor 305 can be driven by a power source such as a solar cell, an electrical battery, electrical mains, an alternator, or may be belt driven from an internal combustion engine if the refrigeration system is used in a vehicle. The one or more expansion devices can be a thermal expansion valve, an electronic expansion valve, a metering device, a capillary tube etc. In some embodiments, a check valve is fluidically coupled proximate an expansion device in order to inhibit reverse flow (e.g., check 318 is fluidically coupled before (or at) the second expansion device 317 inlet and after (or at) the second expansion device 317 outlet). In some embodiments, the first heat exchanger 310 condenses the two-phase fluid that has been compressed by the compressor 305. In some embodiments, the second heat exchanger 320 vaporizes or evaporates the two-phase fluid that has been condensed by the first heat exchanger 310, providing cooling for intended use.

[0046] The receiver drier 330 temporarily stores the two-phase fluid and / or absorbs moisture, debris, or other undesirable substances from a received two-phase fluid. The receiver drier 330 can be disposed between the first heat exchanger 310 and the first expansion device 315. In some embodiments, the receiver drier 330 is fluidically coupled with a reservoir 335 via an electronic valve 340. The electronic valve 340 can be operated by the004210-5029-WQcontroller 325 to increase a charge level of the two-phase fluid (e.g., an amount of two-phase contained in the first loop) in accordance with a determination that the charge level is below a predetermined level. The receiver drier 330 can include one or more sensors communicatively coupled with the controller 325 that provide additional operational data to the controller 325.

[0047] The accumulator 345 restricts liquid two-phase fluid from entering one or more components of the first loop. For example, the accumulator 345 can temporarily store excess liquid two-phase fluid from being provided to the compressor 305 to prevent damage to the compressor 305. In some embodiments, the accumulator 345 disposed between the second heat exchanger 320 and the compressor 305. In some embodiments, the accumulator 345 is fluidically coupled with a flow control valve 350. The flow control valve 350 can be operated by the controller 325 to selectively restrict or permit flow of the two-phase fluid to the compressor 305. The accumulator 345 can also include one or more sensors communicatively coupled with the controller 325 that provide additional operational data to the controller 325. Although not shown, in some embodiments, a reservoir can be fluidically coupled to the accumulator 345 via an electronic valve such that a charge level of the two-phase fluid can be adjusted as described above.

[0048] It should be noted that depending on the operation and performance of the first example thermal management system 301, condensed two-phase fluid at the receiver drier 330 and / or the vaporized and / or evaporated two-phase fluid at the accumulator 345 can be in the form of a liquid, a vapor, or a mixture of liquid and vapor.

[0049] Turning to the second loop of the first example thermal management system 301, the second loop, in some embodiments, includes a respective heat exchanger (e.g., a third heat exchanger 375) and air mover 380. As the single-phase fluid moves through the second loop, the third heat exchanger 375 and the air mover 380 can be used adjust a pressure and / or temperature of the single-phase fluid. The second loop of the first example thermal management system 301 further includes a heat source and / or a heat sink 395 that adds heat into the second loop or draws heat from the second loop. In some embodiments, the second loop further includes a pump 370 configured to cause the single-phase fluid to move through the second the second loop at different flow rates. The controller 325 is communicatively coupled to pump 370 and is configured to adjust a pump speed (or disable or enable the pump 370), and thereby the flow rate, based on the sensor data. The second loop is fluidically coupled to the first loop of the first example thermal management system 301 via a singlephase to two-phase fluid heat exchanger as described above in reference to Figures 1 A-004210-5029-WQ2B. For example, in Figures 3A, the second loop is fluidically coupled to the first loop via the second heat exchanger 320. The second loop includes respective sensors (e.g., sensors 365c) for providing operational data to the controller 325.

[0050] The one or more sensors of the first loop and the second loop are configured to measure temperature and / or pressure of the two-phase fluid and / or the single-phase fluid, the temperature of components or areas thermally coupled with the first loop and / or the second loop, and / or the overall operation of the first loop, the second loop, and / or the first example thermal management system 301. For example, the one or more sensors can measure the temperature and / or pressure of condensed and / or vaporized and / or evaporated two-phase fluid, as well at the temperature and / pressure of the single-phase fluid. The measured temperature and pressure can be used to determine cooling or heating requirements of the first example thermal management system 301, a current charge level of the first loop and / or the second loop, and / or any adjustments to components of the first example thermal management system 301. More specifically, the controller 325 can use the operational data provided by the one or more sensors to control the operation (e.g., adjusting an operating speed of a component, disabling a component, and / or enabling a component) of one or more communicatively coupled components.

[0051] As shown in Figure 3 A, the controller 325 can be communicatively coupled with the compressor 305, the one or more air movers 360 and 380, one or more expansion devices, one or more sensors (e.g., sensors 365a-365c), one or more valves (e.g., flow control valve 350 and electronic valve 340). The controller 325 is configured to adjust operation of one or more communicatively coupled components to improve the efficiency of the first example thermal management system 301, ensure that the first example thermal management system 301 operates under safe operating conditions (e.g., to increase the longevity of the system), maintains a user desired temperature and / or system specific temperature.

[0052] In some embodiments, the controller 325 is electrically or wirelessly coupled to an electronic device including but not limited to a display, a receiver, a smartphone or a computer. The controller 325 can provide one or more notifications or signals to be presented or used by the electronic device. For example, the notifications can include audio notifications, such as a beep, alarm, or tune, or visual notifications, such a text or graphic displayed on a screen. The signals include but are not limited to data (e.g., the cooling level, the super-heating level and the refrigerant charge level), warning signals (e.g., the refrigerant charge level is below a predetermined refrigerant charge level), maintenance request or the004210-5029-WQlike. In some embodiments, the controller 325 is configured to receive one or more instructions from the electronic device for adjusting operation of the first example thermal management system 301. For example, the controller 325 can receive one or more instructions for adjusting a temperature of a compartment, defining a desired temperature, defining a desired temperature threshold, adjusting an air-mover speed, adjusting a compressor speed, adjusting a pump speed, etc.

[0053] Figure 3B shows a second example thermal management system 302. The second example thermal management system 302 is substantially analogous to the first example thermal management system 301. In the second example thermal management system 302, the second loop is fluidically coupled with the first heat exchanger 310 (instead of the second heat exchanger 320). As described above in reference to Figures 3 A, the second loop includes a respective heat exchanger (e.g., a fourth heat exchanger 385) and air mover 390. As the single-phase fluid moves through the second loop, the fourth heat exchanger 385 and the air mover 390 can be used adjust a pressure and / or temperature of the single-phase fluid. The second loop of the second example thermal management system 302 further includes a heat source and / or a heat sink 395 that adds heat into the second loop or draws heat from the second loop. The second loop is fluidically coupled to the first loop of the second example thermal management system 302 via a single-phase to two-phase fluid heat exchanger as described above in reference to Figures 1 A-2B. In the second example thermal management system 302, the second loop also includes respective sensors (e.g., sensors 365d) for providing operational data to the controller 325. The second example thermal management system 302 further includes a pump 370 fluidically coupled with the second loop. The pump 370 is configured to adjust flow rates of the single-phase fluid of the second loop as discussed above in reference to Figure 3 A.

[0054] Figure 3C shows a third example thermal management system 303, in accordance with some embodiments. The third example thermal management system 303 is generally analogous to the second example thermal management system 302 and the first example thermal management system 301. The third example thermal management system 303 includes the second loop, fluidically coupled to the first loop via the second heat exchanger 320 (e.g., as described in reference to Figure 3 A and the first example thermal management system) and a third loop, fluidically coupled to the first loop via the first heat exchanger 310 (e.g., as described in reference to Figure 3B and the second example thermal management system). As described above in reference to Figures 3 A, the second loop includes the third004210-5029-WQheat exchanger 375 and air mover 380. As the single-phase fluid moves through the second loop, the third heat exchanger 375 and the air mover 380 can be used adjust a pressure and / or temperature of the single-phase fluid in the second loop. The second loop is fluidically coupled to the first loop of the third example thermal management system 303 via a singlephase to two-phase fluid heat exchanger as described above in reference to Figures 1 A-2B. In the third example thermal management system 303, the second loop also includes the sensors 365c for providing operational data to the controller 325. As described above in reference to Figures 3B, the third loop includes the fourth heat exchanger 385 and air mover 390. As the single-phase fluid moves through the second loop, the fourth heat exchanger 385 and the air mover 390 can be used adjust a pressure and / or temperature of the single-phase fluid in the third loop. The third loop is fluidically coupled to the first loop of the third example thermal management system 303 via a single-phase to two-phase fluid heat exchanger as described above in reference to Figures 1 A-2B. In the third example thermal management system 303, the third loop also includes the sensors 365d for providing operational data to the controller 325.

[0055] In some embodiments, the second loop and / or the third loop of the third example thermal management system 303 further includes a pump 370 that is configured to cause a single-phase fluid to move through the second loop and / or the third loop at different flow rates (e.g., as described in reference to Figures 3A and 3B, the first example thermal management system 301, and the second example thermal management system 302). In some embodiments, the second loop and / or the third loop of the third example thermal management system 303 further includes a heat source and / or a heat sink 395 that adds heat into the second loop and / or the third loop or draws heat from the second loop and / or the third loop. In some embodiments, the one or both of the second loop and / or the third loop of the third example thermal management system 303 is reversible (e.g., a flow direction of the single phase fluid through the second loop and / or the third loop may be reversed).

[0056] The above configurations are non-limiting. In some embodiments, the first heat exchanger 310 and the second heat exchanger 320 are single-phase to two-phase fluid heat exchangers (e.g., sharing a single-phase fluid loop or each having a respective single-phase fluid loop). In some embodiments, one or more components of the example thermal management systems are optional. In some embodiments, the single-phase to two-phase fluid heat exchanger can be used with other refrigeration systems. For example, the single-phase to004210-5029-WQtwo-phase fluid heat exchanger can be used with a refrigeration loop that does not include a reversing valve or second expansion device.

[0057] Figure 4 is a block diagram illustrating controller, in accordance with some embodiments. In some embodiments, the controller 325 is, or includes control circuitry for operating an thermal management system (e.g., thermal management systems 301-303; Figures 3A-3C). In some embodiments, the controller 325 includes one or more processors 402, one or more communication interfaces 404, memory 408, and one or more communication buses 406 for interconnecting these components (sometimes called a chipset). In accordance with some embodiments, the controller 325 is coupled to one or more sensors 365 (e.g., temperature sensors, pressure sensors, current sensors, etc.) and a power source 412 (e.g., a battery or electrically-driven motor). In some embodiments, the memory 408 includes high-speed random-access memory, such as DRAM, SRAM, DDR RAM, or other random-access solid-state memory devices; and, optionally, includes non-volatile memory, such as one or more magnetic disk storage devices, one or more optical disk storage devices, one or more flash memory devices, or one or more other non-volatile solid state storage devices. The memory 408, optionally, includes one or more storage devices remotely located from the one or more processors 402. The memory 408, or alternatively the non-volatile memory within the memory 408, includes a non-transitory computer readable storage medium.

[0058] In some embodiments, the memory 408, or the non-transitory computer readable storage medium of the memory 408, stores the following programs, modules, and data structures, or a subset or superset thereof: operating logic 414 including procedures for handling various basic system services and for performing hardware dependent tasks; communication module 416 for communicatively-connecting the controller 325 to other computing devices (e.g., vehicular control system or client device) via one or more networks (e.g., the Internet); interface module 417 for presenting information to a user and detecting user input(s) (e.g., in conjunction with communication interface(s) 404); state module 418 for setting and / or adjusting an operating mode or state of the thermal management system (e.g., heating mode, cooling mode, de-icing mode, etc.); battery monitoring module 419 for distributing to and / or monitoring power of one or more components of the refrigeration system; and database 420 storing data for use in governing operation of an thermal management system (e.g., thermal management systems 301-303; Figures 3A-3C). The database 420 can include but is not limited to: sensor information 422 storing information regarding one or more sensors associated with the conditioning system (e.g., temperature data,004210-5029-WQpressure data, and / or current data), component settings 424 storing information regarding one or more components of the conditioning system (e.g., operational settings, such as speed and power), and user information 426 storing information regarding user preferences, settings, history, etc.

[0059] Each of the above identified elements may be stored in one or more of the previously mentioned memory devices and corresponds to a set of instructions for performing a function described above. The above identified modules or programs (i.e., sets of instructions) need not be implemented as separate software programs, procedures, or modules, and thus various subsets of these modules may be combined or otherwise re-arranged in various embodiments. In some embodiments, the memory 408, optionally, stores a subset of the modules and data structures identified above. Furthermore, the memory 408, optionally, stores additional modules and data structures not described above, such as a vehicle module for interfacing between the vehicle and the conditioning system.

[0060] Figures 5A-5D illustrate a straight design heat exchanger 500, in accordance with some embodiments. Figure 5A illustrates an isometric view of the straight design heat exchanger 500. The straight design heat exchanger 500 includes a housing 502 with a rectangular body configuration. A single-phase fluid inlet 510 is positioned at a lower portion of the housing 502, and a single-phase fluid outlet 512 is positioned at an upper portion of the housing 502. A two-phase fluid inlet 514 is positioned at a lower portion of the housing 502, and a two-phase fluid outlet 516 is positioned at an upper portion of the housing 502. In some embodiments, a single-phase fluid is a coolant (e.g., water, glycol, water-glycol mixture) flows from the single-phase fluid inlet 510 to the single-phase fluid outlet 512, and a two-phase fluid is a refrigerant (e.g., R134a, R1234yf, R290, R744) flows from the two-phase fluid inlet 514 to the two-phase fluid outlet 516. In some embodiments, the straight design heat exchanger 500 is configured for coolant-to-refrigerant heat exchange and may operate as a chiller (evaporator) to cool the coolant or as a coolant heater (condenser) to heat the coolant.

[0061] Figure 5B illustrates a cutaway isometric view of straight design heat exchanger 500. The straight design heat exchanger 500 includes a brazed enclosure 518 that forms an inner portion of the housing 502. The cutaway reveals the internal arrangement of components within the housing. Microchannel tubes 504 are arranged in a stacked configuration within the housing 502, providing flow paths for the two-phase fluid (e.g., refrigerant) while maximizing a surface area of the microchannel tubes 504. Baffles 506 are disposed within the housing 502 and positioned between adjacent groups of microchannel tubes 504. The baffles 506 guide the004210-5029-WQflow of the single-phase fluid (e.g., coolant) through the housing 502 in a serpentine pattern, directing the single-phase fluid to flow perpendicularly across the microchannel tubes 504. Evaporator end tanks 508 are positioned at an end of the microchannel tubes 504 and are fluidically coupled to the microchannel tubes 504 to distribute and collect the two-phase fluid. In some embodiments, the single-phase fluid fills or generally fills the brazed enclosure 518 such that the microchannel tubes 504 are submerged in the single-phase fluid.

[0062] Figure 5C illustrates a single-phase fluid flow path through the straight design heat exchanger 500. Figure 5C depicts a cross-sectional front view showing the internal arrangement of microchannel tubes 504 and baffles 506 within the housing 502. The singlephase fluid inlet 510 is positioned at a lower side of the housing 502, and the single-phase fluid outlet 512 is positioned at an upper side of the housing 502. In some embodiments, the singlephase fluid inlet 510 and the single-phase fluid outlet 512 are positioned at either the lower side and / or the upper side, depending on a number of groups of microchannel tubes 504 in the straight design heat exchanger 500. The single-phase fluid (e.g., coolant) enters through the single-phase fluid inlet 510 and is directed through the housing 502 in a serpentine pattern formed by the baffles 506, flowing horizontally across the microchannel tubes 504 in alternating directions before exiting through the single-phase fluid outlet 512. The baffles 506 also cause the single-phase fluid to flow perpendicularly across the microchannel tubes 504, creating a cross-flow or cross-counter-flow configuration that maximizes heat transfer between the single-phase fluid and the two-phase fluid flowing within the microchannel tubes 504.

[0063] Figure 5D illustrates a two-phase fluid flow path through the straight design heat exchanger 500. Figure 5D depicts a cross-sectional front view showing the two-phase fluid flow through the microchannel tubes 504 within the housing 502. The two-phase fluid inlet 514 is positioned at the lower side of the heat exchanger 500, and the two-phase fluid outlet 516 is positioned at the upper side of the heat exchanger 500. In some embodiments, the two-phase fluid inlet 514 and the two-phase fluid outlet 516 are positioned at either the lower side and / or the upper side, depending on a number of groups of microchannel tubes 504 in the straight design heat exchanger 500. The two-phase fluid (e.g., refrigerant) enters through the two-phase fluid inlet 514, flows through the evaporator end tanks 508, travels through the microchannel tubes 504, and exits through the two-phase fluid outlet 516. In some embodiments, the two-phase fluid makes multiple passes through the microchannel tubes 504 before exiting through the two-phase fluid outlet 516.004210-5029-WQ

[0064] Figures 6A-6E illustrate a U-shaped design heat exchanger 600, in accordance with some embodiments. The U-shaped design heat exchanger 600 is similar to the straight design heat exchanger 500 described above in reference to Figures 5A-5D, with certain structural differences as described below.

[0065] Figure 6A illustrates an isometric view of the U-shaped design heat exchanger 600 showing the connections and flow directions. The U-shaped design heat exchanger 600 includes a housing 602 with a rectangular body configuration. A single-phase fluid inlet 610 is positioned at an upper-left portion of the housing 602, and a single-phase fluid outlet 612 is positioned at an upper-right portion of the housing 602. A two-phase fluid inlet 614 is positioned at a lower-right portion of the housing 602, and a two-phase fluid outlet 616 is positioned at a lower-left portion of the housing 602. In some embodiments, a single-phase fluid is a coolant (e.g., water, glycol, water-glycol mixture) flows from the single-phase fluid inlet 610 to the single-phase fluid outlet 612, and a two-phase fluid is a refrigerant (e.g., R134a, R1234yf, R290, R744) flows from the two-phase fluid inlet 614 to the two-phase fluid outlet 516. In some embodiments, the U-shaped design heat exchanger 600 is configured for coolant-to-refrigerant heat exchange and may operate as a chiller (evaporator) to cool the coolant or as a coolant heater (condenser) to heat the coolant.

[0066] Figure 6B illustrates an isometric view of an alternate U-shaped design heat exchanger 650 showing the connections and flow directions. The alternate U-shaped design heat exchanger 650 includes the housing 602 with the rectangular body configuration. The single-phase fluid inlet 610 is positioned at a lower-middle portion of the housing 602, and the single-phase fluid outlet 612 is positioned at an upper-middle portion of the housing 602. The two-phase fluid inlet 614 is positioned at a lowermost portion of the housing 602, and the two-phase fluid outlet 616 is positioned at an uppermost portion of the housing 602. While the remainder of Figures 6C-6E illustrate an interior of the U-shaped design heat exchanger 600, similar interior structures / design / flow directions may be applied to alternate U-shaped design heat exchanger 650.

[0067] Figure 6C illustrates a cutaway isometric view of U-shaped design heat exchanger 600. The U-shaped design heat exchanger 600 includes a brazed enclosure 618 that forms an inner portion of the housing 602. Within the brazed enclosure 618, a partition 620 is positioned to separate different flow regions within the housing 602. Baffles 606 are disposed within the housing 602 and are configured to guide the single-phase fluid flow through the housing 602 in a serpentine pattern. Microchannel tubes 604 are disposed within the housing004210-5029-WQand provide flow paths for the two-phase fluid. Evaporator end tanks 608 are positioned at a top end and a bottom end of the U-shaped design heat exchanger 600. The evaporator end tanks 608 are fluidically coupled to the microchannel tubes 604. In some embodiments, the partition 620 separates a single-phase fluid inlet region 660 from a single-phase fluid outlet region 680, enabling the single-phase fluid to make multiple passes through the housing 602 before exiting.

[0068] Figure 6D illustrates single-phase fluid flow through heat U-shaped design exchanger 600. Figure 6D includes a perspective view of the U-shaped design heat exchanger 600 showing the positions of the coolant and refrigerant connections, and two cross-sectional views depicting the single-phase fluid (coolant) flow path. The single-phase fluid enters through the single-phase fluid inlet 610, flows through the single-phase fluid inlet region 660 and then the single-phase fluid outlet region 680 in a serpentine pattern guided by the baffles 606, and exits through the single-phase fluid outlet 612. The partition 620 and baffles 606 direct the single-phase fluid to flow perpendicularly across the microchannel tubes 604, creating a cross-flow or cross-counter-flow configuration.

[0069] Figure 6E illustrates a two-phase fluid flow path through the U-shaped design heat exchanger 600. Figure 6D includes a perspective view of the U-shaped design heat exchanger 600 showing the positions of the coolant and refrigerant connections, and two cross-sectional views depicting the two-phase fluid flow through the microchannel tubes 604 within the housing 602. The two-phase fluid enters through the two-phase fluid inlet 614 flows through each of the microchannel tubes 604 and the evaporator end tanks 608 of the single-phase fluid outlet region 680 and then each of the microchannel tubes 604 and the evaporator end tanks 608 of the single-phase fluid inlet region 660 in a serpentine pattern, and exits through the two-phase fluid outlet 616. In some embodiments, the two-phase fluid inlet 514 and the two-phase fluid outlet 516 are positioned at either the lower side and / or the upper side, depending on a number of groups of microchannel tubes 604 in the U-shaped design heat exchanger 600. In some embodiments, the two-phase fluid makes multiple passes through the microchannel tubes 604 before exiting through the two-phase fluid outlet 616.

[0070] Although some of various drawings illustrate a number of logical stages in a particular order, stages that are not order dependent may be reordered and other stages may be combined or broken out. While some reordering or other groupings are specifically mentioned, others will be obvious to those of ordinary skill in the art after reading this004210-5029-WQdisclosure, so the ordering and groupings presented herein are not an exhaustive list of alternatives.

[0071] Having thus described system -block diagrams and then example refrigeration systems, attention will now be directed to certain example embodiments.Example Aspects

[0072] A few example aspects will now be briefly described.

[0073] (Al) In accordance with some embodiments, a heat exchanger is disclosed. The heat exchanger includes a housing. The housing includes a predetermined number of channels disposed along a first direction within the housing, and a predetermined number of baffles. Each baffle of the predetermined number of baffles is disposed at distinct portion within the housing along a second direction, perpendicular to the first direction. The heat exchanger includes a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels and a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels. The heat exchanger further includes a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing and a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing. The second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles (e.g., the portions of the housing at which the baffles are disposed).

[0074] (A2) In some embodiments of Al, the first flow of the two-phase fluid flows along the first direction; and the second flow of the single-phase fluid flows, at least partially, in the second direction.

[0075] (A3) In some embodiments of any one of A1-A2, the single-phase fluid substantially fills the housing. In some embodiments, the predetermined number of channels are submerged in the single-phase fluid.

[0076] (A4) In some embodiments of any one of A1-A3, each channel of the predetermined number of channels is one of a microchannel, a multiport channel, a multiport micro-channel.

[0077] (A5) In some embodiments of any one of A1-A4, the predetermined number of channels include a first channel and a second channel. The first channel and the second channel are disposed along the first direction, and the first channel and the second channel on distinct planes.

[0078] (A6) In some embodiments of A5, the first channel and the second channel include respective plurality of microchannels, the respective plurality of microchannels of the first channel and the second channel are the same.

[0079] (A6.5) In some embodiments of A5, the first channel and the second channel include respective plurality of microchannels, the respective plurality of microchannels of the first channel and the second channel are the distinct.

[0080] (A7) In some embodiments of any one of A5-A6.5, the predetermined number of baffles causes the single-phase fluid flow to pass the first channel and the second channel in a perpendicular direction.

[0081] (A8) In some embodiments of any one of A1-A7, the predetermined number of channels and the predetermined number of baffles are selected such that the two-phase fluid flow passes over the single-phase fluid at least once.

[0082] (A9) In some embodiments of A8, the predetermined number of channels and the predetermined number of baffles are selected such that the two-phase fluid flow passes over the single-phase fluid at least twice.

[0083] (A9.5) In some embodiments of any one of A1-A9, the predetermined number of channels and the predetermined number of baffles are selected such that there is a predetermine ratio of passes between the first flow of the two-phase fluid and the second flow of a single-phase fluid.

[0084] (A10) In some embodiments of any one of A1-A9.5, the heat exchanger is configured to operate as a condenser of a heating, ventilation, and air-cooling system.

[0085] (Al 1) In some embodiments of any one of A1-A9.5, the heat exchanger is configured to operate as an evaporator of a heating, ventilation, and air-cooling system.

[0086] (A12) In some embodiments of any one of Al-All, the two-phase fluid is a lower pressure refrigerant selected from R134a, R1234yf, or R290.

[0087] (A13) In some embodiments of any one of A1-A12, the two-phase fluid is R744 (CO2).004210-5029-WQ

[0088] (A14) In some embodiments of any one of A1-A13, the heat exchanger is configured to selectively operate as a chiller to cool the single-phase fluid or as a coolant heater to heat the single-phase fluid.

[0089] (A15) In some embodiments of any one of A1-A14, the heat exchanger is configured for battery thermal management.

[0090] (Al 6) In some embodiments of any one of Al -Al 5, the two-phase fluid is a refrigerant, and the single-phase fluid is a liquid.

[0091] (Al 7) In some embodiments of any one of Al -Al 6, the housing is formed of brazed sheet metal.

[0092] (Al 8) In some embodiments of any one of Al -Al 7, the predetermined number of baffles are brazed onto an interior surface of the housing.

[0093] (Al 9) In some embodiments of any one of Al -Al 8, the housing is formed of plastic.

[0094] (A20) In some embodiments of any one of Al -Al 9, the predetermined number of baffles are integrally formed with the housing.

[0095] (A21) In some embodiments of any one of A1-A20, the two-phase fluid is R744 (CO2).

[0096] (A22) In some embodiments of any one of A1-A21, the heat exchanger is configured for battery thermal management.

[0097] (Bl) In accordance with some embodiments, a refrigeration system (e.g., a thermal management system) is disclosed. The refrigeration system includes a compressor; a first heat exchanger fluidically coupled to the compressor; an expansion device fluidically coupled to the first heat exchanger; and a second heat exchanger fluidically coupled to the expansion device and the compressor. The first heat exchanger and / or the second heat exchanger are heat exchangers in accordance with any of one of A1-A14. A two-phase fluid flows through the refrigeration system, and a single-phase fluid flows through a single-phase fluid loop fluidically coupled with a heat exchanger in accordance with any of one of A1-A14.

[0098] (B2) In some embodiments of Bl, the single-phase fluid loop includes a third heat exchanger.

[0099] (B3) In some embodiments of any one of B1-B2, the single-phase fluid loop includes a pump.004210-5029-WQ

[0100] (B4) In some embodiments of any one of B1-B3, the single-phase fluid loop includes an air mover device.

[0101] (B5) In some embodiments of any one of B1-B4, the refrigeration system includes another air mover.

[0102] (B6) In some embodiments of any one of B1-B5, the refrigeration system includes one or more sensors and a controller communicatively coupled to the one or more sensors and the compressor. The controller is configured to obtain operating data indicative of cooling requirements and adjust a speed of the compressor based on the operating data.

[0103] (B7) In some embodiments of any one of B1-B6, the refrigeration system includes a single-phase fluid loop including a pump communicatively coupled to the controller. The controller is configured to adjust a speed of the pump based on the operating data.

[0104] (Cl) In accordance with some embodiments, a non-transitory, computer-readable storage medium including instructions performed by one or more processors of a thermal management system in accordance with any one of B1-B7 is disclosed. The instructions, when performed by the one or more processors of the thermal management system, cause the thermal management system to operate in accordance with any one of A1-B7.

[0105] (C2) In accordance with some embodiments, a method performed by a thermal management system in accordance with any one of B1-B7 is disclosed. The method includes operations for causing the thermal management system to operate in accordance with any one of A1-B7.

[0106] It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first valve could be termed a second valve, and, similarly, a second valve could be termed a first valve, without departing from the scope of the various described embodiments. The first valve and the second valve are both valves, but they are not the same valve unless explicitly stated.

[0107] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and / or”004210-5029-WQas used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0108] As used herein, the term “if’ is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting” or “in accordance with a determination that,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event]” or “in accordance with a determination that [a stated condition or event] is detected,” depending on the context.

[0109] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the scope of the claims to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen in order to best explain the principles underlying the claims and their practical applications, to thereby enable others skilled in the art to best use the embodiments with various modifications as are suited to the particular uses contemplated.

Claims

1. 004210-5029-WQWhat is claimed is:

1. A heat exchanger, comprising:a housing comprising:a predetermined number of channels disposed along a first direction within the housing, anda predetermined number of baffles, each baffle of the predetermined number of baffles disposed at a distinct portion within the housing along a second direction, perpendicular to the first direction;a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels;a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels;a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing, wherein the single-phase fluid at least partially fills the housing such that the predetermined number of channels are at least partially submerged in the single-phase fluid, and wherein the second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles; anda second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing.

2. The heat exchanger of claim 1, wherein:the first flow of the two-phase fluid flows along the first direction; andthe second flow of the single-phase fluid flows, at least partially, in the second direction.

3. The heat exchanger of claim 1, wherein the single-phase fluid generally fills the housing, (e.g., wherein the predetermined number of channels are submerged in the single-phase fluid)4. The heat exchanger of claim 1, wherein each channel of the predetermined number of channels is one of a microchannel, a multiport channel, a multiport micro-channel.

5. The heat exchanger of claim 1, wherein the predetermined number of channels include a first channel and a second channel, wherein i) the first channel and the second channel are004210-5029-WQdisposed along the first direction and ii) the first channel and the second channel are on distinct planes.

6. The heat exchanger of claim 5, wherein the first channel and the second channel include a respective plurality of microchannels, the respective plurality of microchannels of the first channel and the second channel are the same.

7. The heat exchanger of claim 5, wherein the predetermined number of baffles causes the second flow of the single-phase fluid to pass the first channel and the second channel in a perpendicular direction.

8. The heat exchanger of claim 1, wherein the predetermined number of channels and the predetermined number of baffles are selected such that the first flow of the two-phase fluid passes over the single-phase fluid at least once.

9. The heat exchanger of claim 8, wherein the predetermined number of channels and the predetermined number of baffles are selected such that the first flow of the two-phase fluid passes over the single-phase fluid at least twice.

10. The heat exchanger of claim 1, wherein the heat exchanger is configured to operate as a condenser of a heating, ventilation, and air-cooling system.

11. The heat exchanger of claim 1, wherein the heat exchanger is configured to operate as an evaporator of a heating, ventilation, and air-cooling system.

12. The heat exchanger of claim 1, wherein the two-phase fluid is a refrigerant, and the singlephase fluid is a liquid.

13. The heat exchanger of claim 1, wherein the predetermined number of baffles are brazed onto an interior surface of the housing.

14. The heat exchanger of claim 1, wherein heat is transferred between the two-phase fluid flowing through the predetermined number of channels and the single-phase fluid flowing within the housing as the single-phase fluid flows over and between the predetermined number of channels.

15. The heat exchanger of claim 1, wherein the housing is formed of plastic.004210-5029-WQ16. The heat exchanger of claim 1, wherein the predetermined number of baffles are integrally formed with the housing.

17. The heat exchanger of claim 1, wherein the heat exchanger is configured for battery thermal management.

18. The heat exchanger of claim 1, wherein heat is transferred between the two-phase fluid flowing through the predetermined number of channels and the single-phase fluid flowing within the housing as the single-phase fluid flows over and between the predetermined number of channels.

19. A refrigeration system, comprising:a compressor;a heat exchanger fluidically coupled to the compressor; andan expansion device fluidically coupled to the first heat exchanger;wherein the heat exchanger includes:a housing comprising:a predetermined number of channels disposed along a first direction within the housing, anda predetermined number of baffles, each baffle of the predetermined number of baffles disposed at a distinct portion within the housing along a second direction, perpendicular to the first direction;a first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of a two-phase fluid through the predetermined number of channels;a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels;a second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of a single-phase fluid through the housing, wherein the single-phase fluid at least partially fills the housing such that the predetermined number of channels are at least partially submerged in the single-phase fluid, and wherein the second flow of the singlephase fluid is guided through the housing based on the predetermined number of baffles; and a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing.004210-5029-WQ20. A method comprising:at a heat exchanger comprising a housing that comprises:a predetermined number of channels disposed along a first direction within the housing, anda predetermined number of baffles, each baffle of the predetermined number of baffles disposed at a distinct portion within the housing along a second direction, perpendicular to the first direction;receiving a two-phase fluid at a first fluid inlet of the heat exchanger, the first fluid inlet fluidically coupled to the predetermined number of channels and configured to facilitate a first flow of the two-phase fluid through the predetermined number of channels;receiving a single-phase fluid at a second fluid inlet of the heat-exchanger, the second fluid inlet fluidically coupled to the housing and configured to facilitate a second flow of the single-phase fluid through the housing, wherein the single-phase fluid at least partially fills the housing such that the predetermined number of channels are at least partially submerged in the single-phase fluid, and wherein the second flow of the single-phase fluid is guided through the housing based on the predetermined number of baffles;transferring heat from the single-phase fluid to the two-phase fluid;releasing the two-phase fluid via a first fluid outlet fluidically coupled to the predetermined number of channels and configured to facilitate the first flow of the two-phase fluid from the predetermined number of channels; andreleasing the single-phase fluid via a second fluid outlet fluidically coupled to the housing and configured to facilitate the second flow of the single-phase fluid from the housing.

Images