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