ADVANCED VEHICLE HEAT EXCHANGER

A heat exchanger includes a housing. A first cooling block is defined within the housing. The first cooling block includes a coolant inlet, a refrigerant inlet, and a first gyroid structure that defines a first set of coolant channels and a first set of refrigerant channels. A second cooling block is defined within the housing. The second cooling block includes a coolant outlet, a refrigerant outlet, and a second gyroid structure that defines a second set of coolant channels and a second set of refrigerant channels. A perforated barrier plate is interposed between the first cooling block and the second cooling block. The first set of coolant channels is in fluid communication with the second set of coolant channels via perforations in the barrier plate. The first set of refrigerant channels is in fluid communication with the second set of refrigerant channels via perforations in the barrier plate.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a heat exchanger, in particular, a heat exchanger in a vehicle.

BACKGROUND OF THE DISCLOSURE

Consumers often compare available features and functionality between vehicles when making a purchasing decision. Accordingly, additional solutions are needed that provide features and functionality that are desirable to consumers.

Energy storage systems such as battery electric vehicles (BEVs) or hybrid electric vehicles (HEVs) include a number of batteries electrically connected in parallel or in series. BEV or HEV batteries have specific temperature operating ranges that are critical for battery life and performance. Because battery charging or discharging may be exothermic, depending on the battery composition and the ambient temperature conditions, BEVs and HEVs are equipped with on-board cooling systems to bring electric vehicle batteries within these operating ranges. It is desirable to have compact, efficient cooling systems that minimize the footprint of on-board cooling systems in BEVs and HEVs.

SUMMARY OF THE DISCLOSURE

According to a first aspect of the present disclosure, a heat exchanger is provided. The heat exchange includes a housing and a first cooling block defined within the housing. The first cooling block comprises a coolant inlet, a refrigerant inlet opposing the coolant inlet, and a first gyroid structure defining a first set of coolant channels and a first set of refrigerant channels. A second cooling block is defined within the housing. The second cooling block comprises a coolant outlet, a refrigerant outlet opposing the coolant outlet, and a second gyroid structure defining a second set of coolant channels and a second set of refrigerant channels. The heat exchanger also includes a perforated barrier plate interposed between the first cooling block and the second cooling block. The first set of coolant channels is in fluid communication with the second set of coolant channels via perforations in the barrier plate, and the first set of refrigerant channels is in fluid communication with the second set of refrigerant channels via perforations in the barrier plate.

Embodiments of the first aspect of the present disclosure can include any one or a combination of the following features:the coolant inlet further includes coolant introduction channels that direct fluid flow into the first set of coolant channels, and the refrigerant inlet further includes refrigerant introduction channels that direct fluid flow into the first set of refrigerant channels;the coolant outlet further includes coolant removal channels that direct fluid flow out of the second set of coolant channels, and the refrigerant outlet further includes refrigerant removal channels that direct fluid flow out of the second set of refrigerant channels;at least one of the coolant introduction channels and the refrigerant introduction channels are defined by the first gyroid structure, and at least one of the coolant removal channels, and refrigerant removal channels are defined by the second gyroid structure;the housing, the first gyroid structure, the second gyroid structure, and the barrier plate are integrally coupled;the first gyroid structure defines a first conical recess proximate the coolant inlet and a second conical recess proximate the refrigerant inlet, the second conical recess extends towards the first conical recess;the second gyroid structure defines a third conical recess proximate the coolant outlet and a fourth conical recess proximate the refrigerant outlet, the fourth conical recess extends towards the third conical recess;the coolant inlet and coolant outlet are arranged on a front panel of the housing, and the refrigerant inlet and refrigerant outlet are arranged on a rear panel of the housing; andcoolant fluid is directed along a coolant path and refrigerant fluid is directed along a refrigerant path, the refrigerant path being in a counter-flow configuration relative to the coolant path.

According to a second aspect of the present disclosure, a heat exchanger is provided. The heat exchanger includes a housing, a first cooling block defined within the housing. The first cooling block comprises a coolant inlet and a refrigerant outlet opposing the coolant inlet. A second cooling block is defined within the housing. The second cooling block comprises a coolant outlet and a refrigerant inlet opposing the coolant outlet. The heat exchanger also includes a first set of cooling channels and a first set of refrigerant channels defined in at least one of the first cooling block and the second cooling block, and a second set of cooling channels and a second set of refrigerant channels defined in at least one of the first cooling block and the second cooling block. The heat exchanger further includes a perforated barrier plate interposed between the first cooling block and the second cooling block, the first set of coolant channels is in fluid communication with the second set of coolant channels via perforations in the barrier plate, and the first set of refrigerant channels is in fluid communication with the second set of refrigerant channels via perforations in the barrier plate.

Embodiments of the second aspect of the present disclosure can include any one or a combination of the following features:a gyroid structure defines at least one of the first set of coolant channels, the second set of coolant channels, the first set of refrigerant channels, and the second set of refrigerant channels;a first plurality of tubes are disposed in the first cooling block and a second plurality of tubes are disposed in the second cooling block, and the first plurality of tubes defines at least one of the first set of coolant channels and the second set of refrigerant channels, and the second plurality of tubes defines at least one of the second set of coolant channels and the first set of refrigerant channels;the first set of coolant channels extend through the first plurality of tubes and the second set of refrigerant channels are defined by a space between each tube of the first plurality of tubes, and the first set of refrigerant channels extend through the second plurality of tubes and the second set of coolant channels are defined by a space between each tube of the second plurality of tubes;a coolant path that directs coolant fluid through the first cooling block, across the barrier plate, and through the second cooling block, and a refrigerant path that directs refrigerant fluid through the first cooling block, across the barrier plate, and through the second cooling block, wherein the refrigerant path directs refrigerant fluid in a counter-flow to the coolant fluid in the coolant path; andthe coolant inlet and coolant outlet are arranged on the same side of the heat exchanger, and the refrigerant inlet and refrigerant outlet are arranged on the same side of the heat exchanger.

According to a third aspect of the present disclosure, a heat exchanger is provided. The heat exchanger includes a housing and a first cooling block defined within the housing. The first cooling block comprises a coolant inlet and a refrigerant outlet opposing the coolant inlet. A second cooling block is defined within the housing. The second cooling block comprises a coolant outlet and a refrigerant inlet opposing the coolant outlet. The heat exchange also includes a perforated barrier plate interposed between the first cooling block and the second cooling block, the perforated barrier plate defining a plurality of perforations on opposing ends of the barrier plate, a first plurality of tubes disposed in the first cooling block, the first plurality of tubes directing coolant fluid from the coolant inlet to the plurality of perforations, and a second plurality of tubes disposed in the second cooling block, the second plurality of tubes directing refrigerant fluid from the refrigerant inlet to the plurality of perforations.

Embodiments of the third aspect of the present disclosure can include any one or a combination of the following features:the first plurality of tubes defines at least one of the first set of coolant channels and the second set of refrigerant channels, and the second plurality of tubes defines at least one of the second set of coolant channels and the first set of refrigerant channels;the first set of coolant channels extend through the first plurality of tubes and the second set of refrigerant channels are defined by a space between each tube of the first plurality of tubes, and w the first set of refrigerant channels extend through the second plurality of tubes and the second set of coolant channels are defined by a space between each tube of the second plurality of tubes;a coolant introduction plate disposed in the first cooling block, the coolant introduction plate being obliquely oriented and extending from a front panel of the housing to a rear panel of the housing, and a refrigerant introduction plate disposed in the second cooling block, the refrigerant introduction plate being obliquely orientated and extending from the rear panel and towards the front panel; andthe first plurality of tubes are coupled to the coolant introduction plate, and the first plurality of tubes each include an inlet, each inlet being flush with the coolant introduction plate, and the second plurality of tubes are coupled to the refrigerant introduction plate, and the second plurality of tubes each include an inlet, each inlet being flush with the refrigerant introduction plate.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to the present preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. In the drawings, the depicted structural elements are not to scale and certain components are enlarged relative to the other components for purposes of emphasis and understanding.

As used herein the term “refrigerant” refers to the fluid used in a refrigeration cycle that is used in an air conditioning or heat pump system. Refrigerant fluids may be phase-change fluids such that the fluid condenses to a liquid when cooled during the refrigeration cycle and is heated to a gas when heating during the refrigeration cycle.

As used herein the term “coolant” refers to a fluid that is cooled in order to remove or dissipate heat from an object or system.

As used herein the term “counterflow” refers to a heat exchanger geometry that uses at least two paths and maximizes the temperature gradient between the at least two fluids in the heat exchanger cavities by operating the flow paths in an antiparallel direction.

As used herein the phrase “manufactured as a single piece” refers to a device that is manufactured in a process that forms a single, unified component or piece, which is cast or manufactured as a whole, without requiring separate manufacturing processes to create a plurality of pieces that are subsequently joined together.

Referring now toFIG.1, depicted is a vehicle12that includes a vehicle body14and a drive unit16. The drive unit16of vehicle12may include a battery system18in aspects where the vehicle12is configured as a battery electric vehicle (BEV) or a hybrid electric vehicle (HEV). The battery system18is in electrical communication with the drive unit16of the vehicle12, such as one or more electric motors that are mechanically coupled to wheels of the vehicle12. The drive unit16of vehicle12may additionally or alternatively include an internal combustion engine (ICE) or a fuel cell to provide operative force for the vehicle12.

As the battery system18provides electricity to the drive unit16, it may be desirable to maintain an operating temperature of the battery system18using a cooling system20to deliver coolant to the battery system18. In particular, the cooling system20may comprise one or more heat exchangers10to efficiently transfer heat from the coolant fluid to a refrigerant fluid.

Referring toFIGS.1-7, the vehicle12includes the heat exchanger10. The heat exchanger10includes a housing30and a first coolant block32defined within the housing30. The first coolant block32includes a coolant inlet34, a refrigerant inlet36opposing the coolant inlet34, and a first gyroid structure38that defines a first set of coolant channels40and a first set of refrigerant channels42. A second cooling block44is also defined within the housing30. The second cooling block44includes a coolant outlet46, a refrigerant outlet48that opposes the coolant outlet46, and a second gyroid structure50that defines a second set of coolant channels52and a second set of refrigerant channels54. A perforated barrier plate56is interposed between the first cooling block32and the second cooling block44. The first set of coolant channels40is in fluid communication with the second set of coolant channels52via perforations in the barrier plate56. The first set of refrigerant channels42is in fluid communication with the second set of refrigerant channels54via perforations in the barrier plate56.

Referring toFIGS.1-10, the heat exchanger10includes the housing30. The housing30includes a front panel60, a rear panel62opposing the front panel60, a bottom panel64and a top panel66extending between the front panel60and the rear panel62, and a first side panel68and a second side panel70opposing the first side panel68. According to various aspects, the housing30can define one of various shapes, such as a quadrilateral shape, a rounded shape, and/or one of other various shapes. According to various aspects, the housing30is configured to enclose various components of the heat exchanger10, as provided herein.

Referring toFIGS.1-10, the housing30of the heat exchanger10may be a fabricated in an additive manufacturing process that manufactures additional components of the heat exchanger10. In other embodiments, the housing30of heat exchanger10may be fabricated in a separate manufacturing process wherein the first cooling block32, second cooling block44, and barrier plate56are attached to the housing30.

Referring toFIGS.7and10, the housing30has a structure that defines at least one coolant path72and at least one refrigerant path74. The coolant path72and the refrigerant path74are in thermal communication, such that fluid in the coolant path72can transfer heat to fluid in the refrigerant path74, heating the fluid in the refrigerant path74and cooling the fluid in the coolant path72, as provided herein.

Referring toFIGS.2-10, the housing30includes the barrier plate56disposed within the housing30. In some examples, the barrier plate56extends across a width and/or depth of the housing30. For example, the barrier plate56can extend from the front panel60to the rear panel62of the housing30such that a first cooling block32and a second cooling block44are defined within the housing30, where both cooling blocks32,44are separated by the barrier plate56. The barrier plate56may be integrally formed in the same machining or manufacturing process as the first cooling block32and/or the second cooling block44. Alternatively, the barrier plate56may be made in a separate machining or manufacturing process such that it is physically attached to the first cooling block32and/or the second cooling block44in subsequent steps.

Referring again toFIGS.2-7, the housing30can enclose one or more gyroid structures. In some examples, the housing30can enclose the first gyroid structure38in the first cooling block32and the second gyroid structure50in the second cooling block44. As used herein, a gyroid structure is a three-dimensional lattice which forms at least two interpenetrating labyrinths. The bulk of the gyroid structure, defined as channels that are not bound by the heat exchanger housing30or the barrier plate56, are intersection-free and infinitely triply periodic minimal surfaces. The bulk of the gyroid structure has a structure that can be approximated through the equation sin ([x] cos [y])+ (sin [y] cos [z])+ (sin [z] cos [x])=0, where x, y, and z are coordinates for a point on a 3-dimensional graph having an x-, y-, and z-axis. Gyroids have large surface-area-to-volume ratios, and when a gyroid structure is incorporated into a heat exchanger, the gyroid structure allows substantial thermal contact between the fluids housed within the passages.

In the embodiments illustrated inFIGS.2-7, the housing30includes the coolant inlet34and the refrigerant inlet36. The coolant inlet34is intended to guide the coolant fluid into the first cooling block32and the refrigerant inlet36is intended to guide the refrigerant fluid into the first cooling block32, where the introduction of the refrigerant fluid may be in a general counter-flow to the coolant fluid. In some aspects, both the coolant inlet34and the refrigerant inlet36are coupled to the housing30. For example, the coolant inlet34and the refrigerant inlet36can be coupled to opposing sides of the housing30, which allows for counter-flow where the refrigerant fluid flows in the opposite direction as the coolant fluid. Further, while the coolant inlet34and refrigerant inlet36may be arranged where the inlet fluid flow is perpendicular to the housing30, it is further contemplated that the coolant inlet34and/or refrigerant inlet36may also form an acute angle between the surface of the inlet34,36and the housing30.

In the embodiments illustrated inFIGS.2-7, the first cooling block32includes coolant introduction channels80that are in fluid communication with the coolant inlet34. In some embodiments, the first gyroid structure38defines the coolant introduction channels80. In such embodiments, the first gyroid structure38may define one of various shapes that, in turn, define the coolant introduction channels80. For example, the first gyroid structure38may define a conical recess82, where the coolant introduction channels80are defined along an outer periphery of the conical recess82. According to various aspects, the coolant introduction channels80have a cross-section that is lesser than the cross-section of the coolant inlet34. In other aspects, the coolant introduction channels80may have a cross-section greater than the first set of coolant channels40. The coolant introduction channels80are in fluid communication with the coolant inlet34and the first set of coolant channels40such that coolant fluid may flow from the coolant inlet34to the first set of coolant channels40. Additionally, it is generally contemplated that the coolant introduction channels80may have a shape defined by the interface of the coolant introduction channels80with the first set of coolant channels40, and where that interface may at least partially determine a flow-rate of the coolant fluid into the first set of coolant channels40.

In the embodiments illustrated inFIGS.2-7, the first cooling block32includes refrigerant introduction channels90that are in fluid communication with the refrigerant inlet36. In some embodiments, the first gyroid structure38defines the refrigerant introduction channels90. In such embodiments, the first gyroid structure38may define one of various shapes that, in turn, define the refrigerant introduction channels90. For example, the first gyroid structure38may define a conical recess82, where the refrigerant introduction channels90are defined along an outer periphery of the conical recess82. In such aspects, the conical recess82may have a shape and/or size that differs from a conical recess that at least partially defines the coolant introduction channels80. According to various aspects, the refrigerant introduction channels90have a cross-section that is lesser than the cross-section of the refrigerant inlet36. In other aspects, the refrigerant introduction channels90may have a cross-section greater than the first set of refrigerant channels42. The refrigerant introduction channels90are in fluid communication with the refrigerant inlet36and the first set of refrigerant channels42such that refrigerant fluid may flow from the refrigerant inlet36to the first set of refrigerant channels42. Additionally, it is generally contemplated that the refrigerant introduction channels90may have a shape defined by the interface of the refrigerant introduction channels90with the first set of refrigerant channels42, and where that interface may at least partially determine a flow-rate of the refrigerant fluid into the first set of refrigerant channels42.

Referring toFIGS.3-7, the first set of coolant channels40are defined in the first cooling block32. In some examples, the first set of coolant channels40extends from the coolant inlet34and towards the refrigerant inlet36. In various aspects, the first gyroid structure38defines the first set of coolant channels40. In such aspects, the first set of coolant channels40may be in direct fluid communication with the coolant inlet34, or the first set of coolant channels40may be in fluid communication with the coolant inlet34via the coolant introduction channels80.

Referring again toFIGS.3-7, the first set of refrigerant channels42are defined in the first cooling block32. In some examples, the first set of refrigerant channels42extends from the refrigerant inlet36and towards the coolant inlet34. In various aspects, the first gyroid structure38defines the first set of refrigerant channels42. In such aspects, the first set of refrigerant channels42may be in direct fluid communication with the refrigerant inlet36, or the first set of refrigerant channels42may be in fluid communication with the refrigerant inlet36via the refrigerant introduction channels90.

As shown in inFIGS.2-7, the first set of coolant channels40is in thermal communication with the first set of refrigerant channels42. The interpenetrating labyrinth network of the first gyroid structure38that defines the first set of coolant channels40and the first set of refrigerant channels42has a large surface area that facilitates heat transfer from cooling fluid housed within the first set of coolant channels40to the refrigerant fluid housed within the first set of refrigerant channels42, thereby cooling the coolant.

According to various aspects, the first set of coolant channels40may extend from the coolant inlet34to a first plurality of perforations100that are defined on an end of the barrier plate56and the first set of refrigerant channels42may extend from the refrigerant inlet36to a second plurality of perforations102that are defined on an opposing end of the barrier plate56. The first plurality of perforations100and the second plurality of perforations102may be such that the coolant fluid and the refrigerant fluid may flow across the barrier plate56and into the second cooling block44. In such aspects, the coolant fluid within the first set of coolant channels40may flow into the second set of coolant channels52, and the refrigerant fluid within the first set of refrigerant channels42may flow into the second set of refrigerant channels54, as provided herein.

The size and number of perforations in the barrier plate56will vary depending on the desired flow characteristics. In some embodiments the perforation size and geometry will be matched to the coolant channels40,52and the refrigerant channels42,54that are coupled to the barrier plate56. In some embodiments, the number of perforations on the barrier plate56will be the same for the coolant path72as it is for the refrigerant path74. In other embodiments, the number of perforations on the barrier plate56may be unequal such that there are more perforations in the barrier plate56for communicating coolant fluid from the first set of coolant channels40to the second set of coolant channels52than there are perforations in the barrier plate56to communicate refrigerant from the first set of refrigerant channels42to the second set of refrigerant channels54. In some embodiments the number of perforations on the barrier plate56be unequal such that there are more perforations in the barrier plate56for communicating refrigerant fluid from the first set of refrigerant channels42to the second set of refrigerant channels54than there are perforations in the barrier plate56to communicate coolant from the first set of coolant channels40to the second set of coolant channels52.

Referring again toFIGS.3-7, the second set of coolant channels52is defined in the second cooling block44. In some examples, the second set of coolant channels52extends from the first plurality of perforations100near the refrigerant outlet48and towards the coolant outlet46. In various aspects, the second gyroid structure50defines the second set of coolant channels52. In such aspects, the second set of coolant channels52may be in direct fluid communication with the coolant outlet46, or the second set of coolant channels52may be in fluid communication with the coolant outlet46via coolant removal channels110.

The second set of refrigerant channels54is defined in the second cooling block44. In some examples, the second set of refrigerant channels54extends from the second plurality of perforations102near the coolant outlet46and towards the refrigerant outlet48. In various aspects, the second gyroid structure50defines the second set of refrigerant channels54. In such aspects, the refrigerant fluid in the second set of refrigerant channels54may flow in parallel, in counter-flow, or obliquely relative to the coolant flow in the second set of coolant channels52. The second set of refrigerant channels54may be in direct fluid communication with the refrigerant outlet48, or the second set of refrigerant channels54may be in fluid communication with the refrigerant outlet48via refrigerant removal channels120.

As shown inFIGS.4-7, the second set of coolant channels52is in thermal communication with the second set of refrigerant channels54. The interpenetrating labyrinth network of the gyroid structure that defines second set of coolant channels52and second set of refrigerant channels54has a large surface area that facilitates heat transfer from cooling fluid housed within the second set of coolant channels52to the refrigerant fluid housed within the refrigerant channels54, thereby cooling the coolant.

In the embodiments illustrated inFIGS.4-7, the second cooling block44includes coolant removal channels110that are in fluid communication with the coolant outlet46. In some embodiments, the second gyroid structure50defines the coolant removal channels110. In such embodiments, the second gyroid structure50may define one of various shapes that, in turn, define the coolant removal channels110. For example, the second gyroid structure50may define a conical recess82, where the coolant removal channels110are defined along an outer periphery of the conical recess82. According to various aspects, the coolant outlet46has a cross-section value that is larger than the cross-section value of the second set of coolant channels52. A transition of coolant flow may be realized via coolant removal channels110that have a cross-section value or values intermediate between that of the coolant outlet46and second set of coolant channels52and that are disposed between the coolant outlet46and the second set of coolant channels52. In some embodiments, the coolant removal channels110are configured to transition coolant fluid flow from the second set of coolant channels52to the coolant outlet46. Additionally, it is generally contemplated that the coolant removal channels110may have a shape defined by the interface of the coolant removal channels110with the second set of coolant channels52, and where that interface may at least partially determine a flow-rate of the coolant fluid out of the second set of coolant channels52.

In the embodiments illustrated inFIGS.4-7, the second cooling block44includes refrigerant removal channels120that are in fluid communication with the refrigerant outlet48. In some embodiments, the second gyroid structure50defines the refrigerant removal channels120. In such embodiments, the second gyroid structure50may define one of various shapes that, in turn, define the refrigerant removal channels120. For example, the second gyroid structure50may define a conical recess82, where the refrigerant removal channels120are defined along an outer periphery of the conical recess82. According to various aspects, the refrigerant outlet48has a cross-section value that is larger than the cross-section value of the second set of refrigerant channels54. A transition of refrigerant flow may be realized via the refrigerant removal channels120that have a cross-section value or values intermediate between that of the refrigerant outlet48and second set of refrigerant channels54and that is disposed between the refrigerant outlet48and the second set of refrigerant channels54. In some embodiments the refrigerant removal channels120are configured to transition refrigerant fluid flow from the second set of refrigerant channels54to the refrigerant outlet48. Additionally, it is generally contemplated that the refrigerant removal channels120may have a shape defined by the interface of the refrigerant removal channels120with the second set of refrigerant channels54, and where that interface may at least partially determine a flow-rate of the refrigerant fluid out of the second set of refrigerant channels54.

According to various aspects, it is generally contemplated that the heat exchanger10can include one or more conical recesses82that define the introduction channels80,90and the removal channels110,120. For example, the first gyroid structure38can define a first conical recess82athat defines the coolant introduction channels80and a second conical recess82bthat defines the refrigerant introduction channels90, where the second conical recess82bopposes the first conical recess82aand extends towards the first conical recess82a. Likewise, the second gyroid structure50can define a third conical recess82cthat defines the coolant removal channels110and a fourth conical recess82dthat defines the refrigerant removal channels120, where the fourth conical recess82dopposes the third conical recess82cand extends towards the third conical recess82c. Additionally, it is further contemplated that each conical recess82a,82b,82cand82dmay define a shape and/or depth that coincides or differs from each other conical recess82a,82b,82cand82d. For example, the first conical recess82aand the third conical recess82cmay have a greater depth into each gyroid structure38,50than the second conical recess82band the fourth conical recess82d. In such examples, the greater depth of the first conical recess82aand the third conical recess82cmay increase an increased rate of coolant flow relative to the rate of refrigerant flow.

Referring now toFIGS.3-7, the heat exchanger10includes the coolant outlet46and the refrigerant outlet48. The coolant outlet46is intended to guide the coolant fluid out of the second cooling block44, and the refrigerant outlet48is intended to guide the refrigerant fluid out of the second cooling block44, where the refrigerant fluid may be in a general counter-flow to the coolant fluid. In some aspects, both the coolant outlet46and the refrigerant outlet48are coupled to the housing30. For example, the coolant outlet46and the refrigerant outlet48can be coupled to opposing sides of the housing30, which allows for counter-flow, where the refrigerant fluid flows in the opposite direction as the coolant fluid. Further, while the coolant outlet46and the refrigerant outlet48may be arranged where the outlets46,48direct a fluid flow that is perpendicular to the housing30. It is further contemplated that the coolant outlet46and/or the refrigerant outlet48may also form an acute angle between the surface of the outlets46,48and the housing30.

Referring now toFIG.7, the coolant path72of the heat exchanger10generally directs coolant fluid through the heat exchanger10. In particular, the coolant path72can direct the coolant fluid from the coolant inlet34, through the coolant introduction channels80and into the first set of coolant channels40. The coolant path72then directs the coolant fluid through the first plurality of perforations100and into the second set of coolant channels52. The coolant fluid is then directed to the coolant removal channels110and out of the coolant outlet46.

Referring again toFIG.7, the refrigerant path74of the heat exchanger10generally directs refrigerant fluid through the heat exchanger10. In particular, the refrigerant path74can direct the refrigerant fluid from the refrigerant inlet36, through the refrigerant introduction channels90, and into the first set of refrigerant channels42. The refrigerant path74then directs the refrigerant fluid through the second plurality of perforations102and into the second set of refrigerant channels54. The refrigerant fluid is then directed to the refrigerant removal channels120and out of the refrigerant outlet48.

As illustrated inFIG.7, the coolant path72can be in a counter-flow configuration relative to the refrigerant path74. This counter-flow permits thermal transfer to occur between the coolant fluid and the refrigerant fluid. In some embodiments, the coolant flow can be reversed, such that the coolant fluid flows in through a coolant outlet46, through a second set of coolant channels52, to the first set of coolant channels40through the barrier plate56, through the coolant introduction channels80, and out of the coolant inlet34. This alternative coolant path would allow for a parallel flow configuration.

Referring toFIGS.1-7, the heat exchanger10may be manufactured by an additive manufacturing process wherein successive layers of material or materials are disposed on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic component. In some embodiments, the housing30, first cooling block32, barrier plate56, and second cooling block44are all made in the same additive manufacturing process. In other embodiments, other methods of fabrication known in the art are possible, such layer-additive processes, layer-subtractive processes, or hybrid processes. In some embodiments the heat exchanger10may be manufactured by a combination of these processes. In some embodiments the heat exchanger10is manufactured by combining an additive manufacturing process with layer-additive processes, layer-subtractive processes, or hybrid process. In some embodiments, the heat exchanger10is manufactured by additively manufacturing one component of the heat exchanger10while using a machining process, such as electrical discharge machining, to fabricate another component of the heat exchanger10. According to various aspects, the heat exchanger10can be made out of any thermally conductive material, such as metals. Ideal metals for use as heat exchanger materials may include nickel, nickel alloys, cobalt, cobalt alloys, chrome moly, titanium, aluminum, aluminum alloys, or a combination thereof.

Referring now toFIGS.8-10, the heat exchanger10can include a first plurality of tubes130within the first cooling block32and a second plurality of tubes132in the second cooling block44. According to various aspects, the coolant inlet34can be in fluid communication with the first plurality of tubes130and the refrigerant inlet36can be in fluid communication with the second plurality of tubes132. In such aspects, the first plurality of tubes130are configured to direct the flow of the coolant fluid from the coolant inlet34, along the first cooling block32, and into the second cooling block44, and the second plurality of tubes132are configured to direct the flow of the refrigerant fluid from the refrigerant inlet36, through the second cooling block44, and into the first cooling block32, as provided herein.

Referring further toFIGS.8-10, the first plurality of tubes130can be disposed within the first cooling block32. In some examples, the first plurality of tubes130can be disposed within the first cooling block32such that a coolant inlet140of the first plurality of tubes130is proximate the coolant inlet34and a coolant outlet142of the first plurality of tubes130is abutting the barrier plate56and generally aligned with the first plurality of perforations100. According to various aspects, each tube of the first plurality of tubes130may include a first segment144that extends away from the coolant inlet34, a bend146at an end of the first segment144, and a second segment148that extends away from the bend146and towards the barrier plate56. Each tube of the first plurality of tubes130may have a shape and/or length that coincides with or differs from each other tube of the first plurality of tubes130. For example, each tube130can be offset from one another such that each tube130is generally the same length and size. According to various aspects, the first plurality of tubes130are configured to define the first set of coolant channels40that direct the coolant fluid away from the coolant inlet34and towards the first plurality of perforations defined on the barrier plate56.

Referring now toFIGS.8and9, the heat exchanger10can include a coolant introduction plate150disposed within the first cooling block32. The coolant introduction plate150can be coupled to the bottom panel64and the top panel66of the housing30. In some examples, the coolant introduction plate150can be obliquely orientated in the first cooling block32such that the coolant introduction plate150abuts the sidewall of the housing30and the barrier plate56. In such examples, the coolant introduction plate's 150 degree of orientation may at least partially coincide with the alignment of the first plurality of tubes130. For example, each tube of the first plurality of tubes130can be coupled to the coolant introduction plate150such that inlets140of the first plurality of tubes130are protruding from, flush with, or recessed from the coolant introduction plate150. According to various aspects, the coolant introduction plate150is configured to define a coolant inlet flow chamber152that permits uniform flow of the coolant fluid into the first plurality of tubes130. In such aspects, the coolant inlet flow chamber152may define one of various shapes, such as a triangular, rounded, prismatic, and/or one of other various shapes that permit coolant flow into the first cooling block32and the first plurality of tubes130. In yet other aspects, the coolant introduction plate150may function as a barrier that redirects the refrigerant fluid towards the refrigerant outlet48as the refrigerant fluid passes through the second plurality of perforations102, as provided herein.

Referring further toFIGS.8-10, the second plurality of tubes132can be disposed within the second cooling block44. In some examples, the second plurality of tubes132can be disposed within the second cooling block44such that an inlet160of the second plurality of tubes132is proximate the refrigerant inlet36and an outlet162of the second plurality of tubes132is abutting the barrier plate56and generally aligned with the second plurality of perforations102. According to various aspects, each tube of the second plurality of tubes132may include a first section164that extends away from the refrigerant inlet36, a bend166at an end of the first section164, and a second section168that extends away from the bend166and towards the barrier plate56. As illustrated inFIGS.8and9, the second plurality of tubes132can be disposed in the second cooling block44and be in a mirrored, parallel, inverted, or another configuration relative to the first plurality of tubes130. Each tube of the second plurality of tubes132may have a shape and/or length that coincides with or differs from each other tube of the second plurality of tubes132. For example, each tube132can be offset from one another such that each tube132is generally the same length and size. According to various aspects, the second plurality of tubes132are configured to define the first set of refrigerant channels42that direct the coolant fluid away from the coolant inlet34and towards the first plurality of perforations100defined on the barrier plate56.

Referring now toFIGS.8and9, the heat exchanger10can include a refrigerant introduction plate170disposed within the second cooling block44. The refrigerant introduction plate170can be coupled to the bottom panel64and the top panel66of the housing30. In some examples, the refrigerant introduction plate170can be obliquely orientated in the second cooling block44such that the refrigerant introduction plate170abuts the sidewall of the housing30and the barrier plate56. In such examples, the refrigerant introduction plate's 170 degree of orientation may at least partially coincide with the alignment of the second plurality of tubes132. For example, each tube132of the second plurality of tubes132can be coupled to the refrigerant introduction plate170such that inlets160of the second plurality of tubes132are protruding from, flush with, or recessed from the refrigerant introduction plate170. According to various aspects, the refrigerant introduction plate170is configured to define a refrigerant inlet flow chamber172that permits uniform flow of the refrigerant fluid into the second plurality of tubes132. In such aspects, the refrigerant inlet flow chamber172may define one of various shapes, such as a triangular, rounded, prismatic, and/or one of other various shapes that permit refrigerant flow into the second cooling block44and the second plurality of tubes132. In yet other aspects, the refrigerant introduction plate170may function as a barrier that redirects the coolant fluid towards the coolant outlet46as the coolant fluid passes through the first plurality of perforations100, as provided herein

Referring now toFIG.10, the coolant path72, directs the coolant fluid through the heat exchanger10. In particular, the coolant path72directs the coolant fluid through the coolant inlet34and into the coolant inlet flow chamber152, where the coolant fluid is directed into the inlets140of the first plurality of tubes130. The coolant fluid then travels through the first plurality of tubes130and the first plurality of perforations100. The coolant fluid is then directed by the refrigerant introduction plate170to a plurality of coolant channels180that are defined between the second plurality of tubes132, where the plurality of coolant channels180define the second set of coolant channels52and have a shape and/or size that is at least partially determined by the placement, size, and/or shape of the second plurality of tubes132. The coolant fluid is then directed along the plurality of coolant channels180and out of the coolant outlet46.

Referring again toFIG.10, the refrigerant path74, in the embodiments shown inFIGS.8-10, directs the refrigerant fluid through the heat exchanger10. In particular, the refrigerant path74directs the refrigerant fluid through the refrigerant inlet36and into the refrigerant inlet flow chamber172, where the refrigerant fluid is directed into the inlets160of the second plurality of tubes132. The refrigerant fluid then travels through the second plurality of tubes132and the second plurality of perforations102. The refrigerant fluid is then directed by the coolant introduction plate150to a plurality of refrigerant channels190that are defined between the first plurality of tubes130, where the plurality of refrigerant channels190define the second set of refrigerant channels190and have a shape and/or size that is at least partially determined by the placement, size, and/or shape of the first plurality of tubes130. The refrigerant fluid is then directed along the plurality of refrigerant channels190and out of the refrigerant outlet48.

As illustrated inFIG.10, the coolant path72can be in a counter-flow configuration relative to the refrigerant path74. This counter-flow permits thermal transfer to occur between the coolant fluid and the refrigerant fluid as the coolant fluid travels through the first plurality of tubes130and the refrigerant fluid travels through the plurality of refrigerant channels190as the coolant fluid travels through the plurality of coolant channels180and the refrigerant fluid travels through the second plurality of tubes132. In some embodiments, the coolant flow can be reversed, such that the coolant fluid flows in through the coolant outlet46, through the plurality of coolant channels180and the first plurality of perforations100, into the first plurality of tubes130, and out of the coolant inlet34. This alternative coolant path permits a parallel flow configuration of the heat exchanger10.

Use of the presently disclosed device may provide for a variety of advantages. For example, the heat exchanger10, by utilizing a first cooling block32, a second cooling block44, and a barrier plate56, permits the utilization of a compact heat exchanger10in a vehicle12. In particular, the use of a gyroid structure, such as the first gyroid structure38and the second gyroid structure50permits efficient thermal transfer, due to the high surface-area-to-volume ratio of the gyroid heat exchanger10, relative to traditional heat exchangers. Additionally, the use of the first plurality of tubes130with the coolant introduction plate150and the second plurality of tubes132with the refrigerant introduction plate170provides for a compact heat exchanger10that can effectively permit thermal transfer in a compact heat exchanger10, relative to traditional heat exchangers.