Counter-flow heat exchanger for battery thermal management applications

A heat exchanger for thermal management of a battery unit having a plurality of battery cell containers each housing one or more battery cells, comprising:

• a rectangular, or generally rectangular, main body portion having a first surface defining a planar, or substantially planar, primary heat transfer surface, said first surface extending between first and second end surfaces that extend perpendicular to, or substantially perpendicular to, said first surface, said main body portion having a plurality of spaced apart tubular channels extending through solid main body portion from said first ends surface to said second end, said plurality of tubular channels forming a plurality of alternating first and second fluid flow passages wherein said plurality of first fluid flow passages and said plurality of second fluid flow passages are arranged so as to alternate through said main body portion and wherein the flow direction of said first fluid flow passages is opposite to the flow direction of said second fluid flow passages, said heat exchanger further comprising:
• a manifold section having a first end surface arranged in face-to-face sealing engagement with one of said first and second end surfaces of said main body portion, said manifold section comprising:
• a plurality of alternating inlet and outlet flow channels formed within said manifold section each extending from a first open end disposed in said first end surface of the manifold section to a second end disposed within said manifold section;
• a first manifold comprising a slot formed in an upper surface of said manifold section and extending into said manifold section establishing fluid communication with of said second ends of one of said plurality of inlet flow channels or said plurality of outlet flow channels;
• and
• a second manifold comprising a row of spaced apart fluid openings formed in said upper surface of said manifold section and extending into said manifold section establishing fluid communication with the second ends of the other one of said plurality of inlet flow channels or said plurality of outlet flow channels;
• wherein said row of spaced apart fluid openings extends generally parallel to and is inwardly disposed with respect to said slot.

A method of making a heat exchanger for thermal management of battery units comprising the steps of:

• providing a plurality of base plate portions, each base plate portion comprising:
• a central, generally planar portion surrounded by a peripheral flange, a portion of said plurality of alternating first and second fluid flow passages being formed within the central generally planar portion of each of said base plate portions, said base plate portions being arranged adjacent to each other and fixed together to form said base plate;
• wherein said first and second fluid flow passages are formed by a plurality of U-shaped embossments formed in said central, generally planar portion of each of said base plate portions, said U-shaped embossments having two elongate branches that terminate at discrete ends wherein said first fluid flow passages are formed between adjacent U-shaped embossments and said second fluid flow passages being formed between the two elongate branches of each of said U-shaped embossments, the second ends of said first fluid flow passages and said first ends of said second fluid flow passages being interconnected by a common fluid collector channel that extends along the width of each of said base plate portions, the first ends of said first fluid flow passages being interconnected by a common inlet header region that extends along the width of each of said base plate portions;
• having the same structure;
• selecting a predetermined number of base plate portions for forming a heat exchanger having predetermined dimensions;
• arranging said predetermined number of base plate portions in side-by-side arrangement and joining said base plate portions together for forming a base plate;
• sealingly arranging a cover plate on top of said base plate for enclosing said first and second fluid flow passages, said cover plate comprising:
• a central, generally planar portion that defines a primary heat transfer surface for contacting at least one battery cell or battery cell container;
• one or more fluid routing slots formed in said cover plate, each fluid routing slot being in communication with said inlet header region formed in each of said base plate portions;
• a series of fluid openings formed in said cover plate inset from said fluid routing slots and extending along the width of the cover plate, each fluid opening being in communication with a corresponding second end of said second fluid flow passages formed in said base plate portions;
• and
• sealingly arranging a manifold cover on said cover plate enclosing said fluid routing slots and said series of fluid openings for forming respective inlet and outlet manifolds for inletting and discharging a heat exchange fluid into said heat exchanger.

A heat exchanger for thermal management of a battery unit having a plurality of battery cell containers each housing one or more battery cells, comprising:

• a main body portion having opposed ends and defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of said battery cell containers;
• a plurality of first fluid flow passages formed within said main body portion, each of said first fluid flow passages having a first end for inletting a fluid into said first fluid flow passages and a second end for discharging said fluid from said first fluid flow passages, said first and second ends defining a flow direction through said first fluid flow passages;
• a plurality of second fluid flow passages formed within said main body portion, each of said second fluid flow passages having a first end for inletting said fluid into said second fluid flow passages and a second end for discharging said fluid from said second fluid flow passages, said first and second ends defining a flow direction through said second fluid flow passages;
• wherein said first and second fluid flow passages are arranged so as to alternate through said main body portion and wherein the flow direction of said first fluid flow passages is opposite to the flow direction of said second fluid flow passages;
• and
• wherein said first and second fluid flow passages are formed by U-shaped flow channels having a pair of elongate fluid branches that are interconnected at one end by a turn portion such that said second ends of said first fluid flow passages are in fluid communication with said first ends of said second fluid flow passages;
• and
• wherein said heat exchanger further comprises:
• an inlet manifold in fluid communication with said first ends of said first fluid flow passages;
• and
• an outlet manifold in fluid communication with said second ends of said second fluid flow passages;
• wherein said inlet and outlet manifolds are arranged adjacent to each other at one end of the main body portion of the heat exchanger, one of said inlet and outlet manifolds being inwardly disposed with respect to the other one of said inlet and outlet manifold and offset with respect thereto.