Heat exchangers for battery thermal management applications with integrated bypass

• US 10,158,151 B2
• Filed: 05/05/2017
• Issued: 12/18/2018
• Est. Priority Date: 05/06/2016
• Status: Active Grant

• Current Assignee: Dana Canada Corporation
• Original Assignee: Dana Canada Corporation
• Inventors: Kenney, Benjamin A., Kamenski, Joseph A.
• Primary Examiner(s): Godo, Olatunji A
• Application Number:
  US15/587,802
• Publication Number:
  US 20170324132A1
• Time in Patent Office: 592 Days
• CPC Class Codes: F28F 2250/06 Derivation channels, e.g. bypass
• CPC Class Codes: F28F 27/02 for controlling the distribution of heat-exchange media between different channels static flow control means in header boxes F28F9/026; arrangements of guide plates or guide vanes F28F9/22, F28F25/12
• CPC Class Codes: F28F 3/00 Plate-like or laminated elements; Assemblies of plate-like or laminated elements specially adapted for movement F28F5/00
• CPC Class Codes: F28F 3/046 the deformations being linear, e.g. corrugations
• CPC Class Codes: F28F 3/12 Elements constructed in the shape of a hollow panel, e.g. with channels F28D1/02, F28D1/03 take precedence
• CPC Class Codes: F28F 9/0248 Arrangements for sealing connectors to header boxes
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A heat exchanger for battery thermal management applications is disclosed. The heat exchanger has at least one internal, two-pass flow passage, the at least one internal, two-pass flow passage having an inlet end and an outlet end and at least a first flow passage portion and at least a second flow passage portion interconnected by a generally U-shaped turn portion. An inlet manifold is in fluid communication with the inlet end of the internal flow passage for delivering an incoming fluid stream to the heat exchanger while an outlet manifold is in fluid communication with the outlet end of the internal flow passage for discharging an outgoing fluid stream from the heat exchanger. A bypass passage fluidly interconnects the incoming fluid stream and the outgoing fluid stream.

Claims

1. A heat exchanger for battery thermal management applications, comprising:

a heat exchanger core defining at least one internal, two-pass flow passage, the at least one internal, two-pass flow passage having an inlet end, an outlet end, at least a first flow passage portion and at least a second flow passage portion, the first and second flow passage portions being interconnected by a generally U-shaped turn portion;

an inlet manifold in fluid communication with said inlet end of said internal flow passage for delivering an incoming fluid stream to said heat exchanger;

an outlet manifold in fluid communication with said outlet end of said internal flow passage for discharging an outgoing fluid stream from said heat exchanger; and

at least one bypass passage fluidly interconnecting said incoming fluid stream and said outgoing fluid stream, said at least one bypass passage allowing fluid from the incoming fluid stream to be diverted to said outlet manifold, at least partially bypassing said at least one internal, two-pass flow passage of said heat exchanger.

2. The heat exchanger as claimed in claim 1, wherein said heat exchanger core comprises:

a base plate having a central, generally planar portion surrounded by a peripheral flange, said at least one internal, two-pass flow passage being formed within the central generally planar portion of said base plate;

a cover plate arranged over top of and in sealing engagement with said base plate enclosing said at least one internal, two-pass flow passage, said cover plate having a central, generally planar portion that defines primary heat transfer surface of said heat exchanger;

wherein the cover plate comprises at least one inlet opening in fluid communication with the inlet manifold and with the inlet end of the at least one internal flow passage; and

at least one outlet opening in fluid communication with the outlet manifold and with the outlet end of the at least one internal flow passage.

3. The heat exchanger as claimed in claim 2, further comprising a manifold cover arranged on top of and in sealing engagement with said cover plate and at least partly defining said inlet and outlet manifolds;

wherein said at least one bypass passage interconnects said inlet manifold and said outlet manifold, the at least one bypass passage being provided in the manifold cover.

4. The heat exchanger as claimed in claim 3, wherein said manifold cover comprises:

an inlet manifold flow channel in fluid communication with the at least one inlet opening of the cover plate for delivering an incoming heat exchange fluid to the inlet end of said at least one internal flow passage;

an outlet manifold flow channel in fluid communication with the at least one outlet opening of the cover plate for receiving said heat exchange fluid from the outlet end of said at least one internal flow passage;

a flow barrier arranged intermediate said inlet and outlet manifold flow channels, wherein each said bypass passage is defined by a gap in the flow barrier.

5. The heat exchanger as claimed in claim 4, wherein said manifold cover further comprises:

a raised, central portion surrounded by a peripheral flange for sealing against said cover plate, said peripheral flange having a bottom planar sealing surface which is sealingly joined to an area of the cover plate surrounding the at least one inlet opening and the at least one outlet opening;

said flow barrier formed within said raised, central portion of said manifold cover and extending along a longitudinal axis thereof, the flow barrier having a bottom surface sealingly joined to an area of the cover plate extending along a line between the at least one inlet opening and the at least one outlet opening.

6. The heat exchanger as claimed in claim 5, wherein said flow barrier comprises at least a first flow barrier segment and a second flow barrier segment, wherein the first and second flow barrier segments are spaced apart from each other by one said gap defining one said bypass passage fluidly interconnecting said inlet manifold flow channel and said outlet manifold flow channel.

7. The heat exchanger as claimed in claim 5, wherein said first flow barrier segment has a first end spaced apart from a corresponding end of said raised, central portion;

and/or

said second flow barrier segment has a first end spaced apart from a corresponding end of said raised, central portion.

8. The heat exchanger as claimed in claim 5, further comprising:

a fluid inlet opening formed in said raised, central portion of said manifold cover in fluid communication with said inlet manifold flow channel; and

a fluid outlet opening formed in said raised, central portion of said manifold cover in fluid communication with said outlet manifold flow channel.

9. The heat exchanger as claimed in claim 8, wherein said fluid inlet opening and said fluid outlet opening are positionable at any location along a length of said inlet and outlet manifold flow channels, respectively.

10. The heat exchanger as claimed in claim 1, wherein said at least one internal, two-pass flow passage is comprised of a series of alternating first flow channels and second flow channels, each of said first flow channels being interconnected to an adjacent second flow channel by a generally U-shaped turn portion;

said first flow channels each having a first end in fluid communication with said inlet manifold, the series of first ends of the first flow channels defining said inlet end; and

said second flow channels each having a second end in fluid communication with said outlet manifold, the series of second ends of said second flow channels defining said outlet end.

11. The heat exchanger as claimed in claim 3, wherein said manifold cover comprises:

an inlet manifold flow channel in fluid communication with the at least one inlet opening of the cover plate for delivering an incoming heat exchange fluid to the inlet end of said at least one internal flow passage;

an outlet manifold flow channel in fluid communication with the at least one outlet opening of the cover plate for receiving said heat exchange fluid from the outlet end of said at least one internal flow passage;

a valve component mounted on said manifold cover in sealing engagement therewith, said valve component comprising;

a valve chamber;

a first inlet in fluid communication with said inlet manifold flow channel and said valve chamber;

a second inlet in fluid communication with said second manifold flow channel and said valve chamber;

an outlet in fluid communication with said valve chamber;

a valve mechanism arranged within said valve chamber for controlling flow between said first inlet and said outlet, the valve mechanism having a first operational state permitting fluid flow from said first inlet to said outlet and a second operational state prevent fluid flow from said first inlet to said outlet; and

wherein said bypass passage is in the form of a fluid opening formed in said inlet manifold flow channel establishing fluid communication between said inlet manifold flow channel and said second manifold flow channel via said valve component.

12. The heat exchanger as claimed in claim 11, wherein said valve mechanism is selected from one of the following alternatives:

a thermal wax motor or a solenoid activated valve.

13. The heat exchanger as claimed in claim 11, wherein said manifold cover further comprises:

a pair of generally parallel embossments formed in the manifold cover, said embossments defining said inlet and outlet manifold flow channels;

a peripheral flange surrounding said pair of generally parallel embossments, said peripheral flange having a bottom planar sealing surface which is sealingly joined to an area of the cover plate surrounding the at least one inlet opening and the at least one outlet opening; and

wherein said embossments are separated and spaced apart from each other by an intermediate portion lying in the same plane as said peripheral flange, the intermediate portion having a bottom surface sealingly joined to an area of the cover plate extending along a line between the at least one inlet opening and the at least one outlet opening.

14. The heat exchanger as claimed in claim 1, wherein said bypass passage fluidly interconnects said first flow passage portion and said second flow passage portion at a location upstream from said U-shaped turn portion.

15. The heat exchanger as claimed in claim 1, wherein said heat exchanger core comprises:

a base plate having a central, generally planar portion surrounded by a peripheral flange, said at least one internal, two-pass flow passage being formed within the central generally planar portion of said base plate;

a cover plate arranged over top of and in sealing engagement with said base plate enclosing said at least one internal, two-pass flow passage, said cover plate having a central, generally planar portion that defines primary heat transfer surface of said heat exchanger;

wherein said at least one internal, two-pass flow passage is comprised of a series of alternating first flow channels and second flow channels, each of said first flow channels being fluidly interconnected to at least one second flow channel by a generally U-shaped turn portion, the first and second flow channels each defining a flow direction through said heat exchanger;

said first flow channels each having a first end in fluid communication with said inlet manifold, the series of first ends of the first flow channels defining said inlet end; and

said second flow channels each having a second end in fluid communication with said outlet manifold, the series of second ends of said second flow channels defining said outlet end;

wherein said at least one bypass passage is formed in said base plate and fluidly interconnects at least one of said first flow channels and at least one of said second flow channels at a location upstream of the generally U-shaped turn portion.

16. The heat exchanger as claimed in claim 15, wherein said at least one bypass passage is formed in said base plate and fluidly interconnects at least one of said first flow channels and at least one of said second flow channels at a location proximal to said outlet end of the at least one two-pass flow passage.

17. The heat exchanger as claimed in claim 15, wherein the base plate is configured for counter-flow of a fluid through said at least one two-pass flow passage;

wherein said at least one two-pass flow passage comprises a series of alternating first flow channels and second flow channels, each of said first flow channels being fluidly interconnected to an adjacent second flow channel by one said generally U-shaped turn portion;

wherein said first and second flow channels are defined by a plurality of ribs;

wherein each of said at least one bypass passage is defined by a gap in one of said ribs, said gap fluidly interconnecting one of said first flow channels to one of said second flow channels;

wherein said at least one bypass passage comprises a bypass passage extending in a transverse direction relative to the flow direction of said series of alternating first and second flow channels and defined by a series of gaps provided in said plurality of ribs, the gaps being aligned in said transverse direction.

18. The heat exchanger as claimed in claim 15, wherein the base plate is configured for U-flow of a fluid through said at least one two-pass flow passage;

wherein said at least one two-pass flow passage comprises a generally U-shaped flow passage having a first flow passage portion, a second flow passage portion and a flow barrier between the first and second flow passage portions;

wherein the inlet end and the outlet end of the internal, two-pass flow passage are both located at a first end of the base plate, and the at least one generally U-shaped turn portion is located proximate to a second end of the base plate;

wherein an inlet manifold portion and an outlet manifold portion are defined at the first end of the base plate, on opposite sides of said flow barrier;

wherein the flow barrier comprises a rib which is provided with at least one gap proximate to the first end of the base plate, said at least one gap defining said at least one bypass passage;

wherein said at least one bypass passage fluidly interconnects the inlet and outlet manifold portions of the base plate.

19. The heat exchanger as claimed in claim 18, wherein said at least one two-pass flow passage comprises a plurality of nested, generally U-shaped flow passages defined by a plurality of ribs.

20. The heat exchanger as claimed in claim 18, wherein a bypass rib portion is provided in the at least one bypass passage fluidly interconnecting the inlet and outlet manifold portions of the base plate.