Patent Description:
Chiller plates for cooling heat-producing devices such as batteries are known. These plates maintain the operating temperature of the heat-producing device within an acceptable operating range by efficiently removing the heat generated by the devices, thereby preventing degradation of the device due to excessive temperatures. Typically, the heat is removed by transfer to a fluid stream that is routed through the plates. In such applications, it is often desirable to maintain a predominantly uniform temperature profile over the surface of the plate. Such a uniform temperature profile can be especially desirable in the cooling of batteries, particularly in applications such as electric or hybrid motor vehicle battery cooling.

Prior known attempts at achieving the aforementioned uniform temperature profile have included the use of a high thermal inertia fluid as the cooling medium. The thermal inertia of a fluid can be characterized by the proportionality between the rate of temperature increase or decrease and the rate of heat input or output required to effect that rate of temperature increase or decrease. A high thermal inertia can be achieved through the use of a single phase fluid (e.g. a liquid) having either a high mass flow rate, a high specific heat capacity as a fluid property, or both. Such an approach has been found to be especially problematic in applications where multiple devices need to be cooled simultaneously, as is typically the case in electric or hybrid motor vehicle battery cooling.

When typical liquid coolants are used in such an application, very high fluid flow rates are required to minimize the undesirable temperature rise of the fluid as it receives heat from the batteries. Placing multiple very high fluid flows in parallel in order to cool the multiple batteries is problematic, as it requires a prohibitively oversized coolant handling system and substantial parasitic power to direct the coolant through the system. Placing the battery cooling devices in series along the coolant circuit is also undesirable, as the coolant temperature will inevitably rise along the series circuit, resulting in a disparity between the temperatures of the individual batteries.

Two-phase refrigerant cooling of batteries in electric or hybrid motor vehicle applications has also been proposed, but has also been found to be problematic. The use of refrigerant has the advantage of providing a cooling fluid with a high effective heat capacity when in the two-phase state, with evaporation of the fluid occurring with effectively no temperature rise. However, once the refrigerant is fully vaporized, any additional heat input will result in superheating of the refrigerant, causing a rapid temperature increase. When such a condition occurs within the battery cooling device, it results in a sharp discontinuity in battery temperature, which can be detrimental to the life and performance of the battery. Furthermore, the dynamic nature of the battery heat loads make it difficult, if not impossible, to maintain a refrigerant flow that does not result in such dry-out phenomena occurring.

<CIT> describes a system for a motor vehicle for heating and/or cooling a battery and a motor-vehicle interior, comprising a coolant circuit which is coupled thermally to the battery by way of a battery heat exchanger, a refrigerating circuit with a condenser, a compressor, a first evaporator for cooling the motor-vehicle interior and a second evaporator for cooling the battery, by the second evaporator being thermally coupled to the coolant circuit by way of an evaporator heat exchanger.

<CIT> describes heat exchanger apparatus wherein a multifluid or at least three-fluid heat exchanger is mounted externally to but in combination with a two-fluid heat exchanger. The multifluid heat exchanger includes three fluid passages or conduits wherein heat energy can be transferred efficiently between at least one of the fluid conduits and each of the other fluid conduits.

<CIT> describes heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers housing one or more battery cells is disclosed. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers.

<CIT> discloses a heat exchanger for a battery constituted of two plates with corrugations forming a cooling flow channel with a serpentine configuration.

According to some embodiments of the invention, a plate assembly for a heat exchanger includes a first plate, a second plate, and an intermediate plate arranged between the first and second plates. The intermediate plate is joined to the first and second plates at peripheral edges to create a sealed periphery of the plate assembly. Corrugations of the intermediate plate provide crests and troughs that are in contact with inwardly facing surfaces of the first and second plates. The intermediate plate separates a first volume defined by the intermediate plate and the inwardly facing surfaces of the first plate from a second volume defined by the intermediate plate and the inwardly facing surfaces of the second plate. In some embodiments the first and second volumes are hydraulically separated from each other between the first and second plates. In other embodiments the first and second volumes are in fluid communication with one another at certain locations within the plate assembly.

In some embodiments, the plate assembly is a battery cooling plate heat exchanger and includes a fluid manifolding area arranged at one end of a lengthwise direction of the plate assembly. A first inlet chamber, first outlet chamber, second inlet chamber, and second outlet chamber are arranged within the fluid manifolding area. The first inlet chamber and the first outlet chamber are part of the first volume, and the second inlet chamber and second outlet chamber are part of the second volume. In some such embodiments the first inlet chamber overlaps with the second outlet chamber in a thickness direction of the plate assembly, and the second inlet chamber overlaps with the first outlet chamber in the thickness direction. In other such embodiments the first inlet chamber overlaps with the second inlet chamber in a thickness direction of the plate assembly, and the first outlet chamber overlaps with the second outlet chamber in the thickness direction.

In some embodiments, the plate assembly includes a first fluid chamber and a second fluid chamber. The first fluid chamber can be arranged in an embossed area of the first plate, and can be in fluid communication with, or can be part of, the first volume. The second fluid chamber can be arranged in an embossed area of the second plate, and can be in fluid communication with, or can be part of, the second volume. A first embossment extends from the intermediate plate towards the first plate, and engages the embossed area of the first plate to partially bound the second fluid chamber. A second embossment extends from the intermediate plate towards the second plate, and engages the embossed area of the second plate to partially bound the first fluid chamber. In some such embodiments the first and second fluid chambers are arranged immediately adjacent one another. In some embodiments the embossed area of the first plate is arranged directly opposite the embossed area of the second plate.

Alternatively, the first and second fluid chambers can be arranged between the first and second plates in a fluid manifolding area of the plate assembly. The first and second fluid chambers can overlap one another in a thickness direction of the plate assembly, and can be separated by a generally planar wall of the intermediate plate. In some embodiments the plate assembly can further include a third and fourth fluid chambers that are also arranged in the fluid manifolding area and that also overlap one another in the thickness direction. The third chamber can also be in fluid communication with, or can be part of, the first volume. The fourth chamber can also be in fluid communication with, or can be part of, the second volume. In some embodiments a bead is formed into one of the first and second plates and extends from an edge of that plate through the fluid manifolding area. The intermediate plate can be joined to the first and second plates in the region of the bead, thereby separating the first fluid chamber from the third fluid chamber and the second fluid chamber from the fourth fluid chamber.

In some such embodiments, the plate assembly includes a first set of nonlinear fluid flow paths that are arranged between the intermediate plate and the first plate. The first set of nonlinear fluid flow paths provide fluid connections between the first fluid chamber and the third fluid chamber. The plate assembly can further include a second set of nonlinear fluid flow paths that are arranged between the intermediate plate and the second plate. The second set of nonlinear fluid flow paths provide fluid connections between the second fluid chamber and the fourth fluid chamber. In some such embodiments, a fluid traveling along the first set of nonlinear fluid flow paths is traveling in a counterflow orientation to a fluid traveling along the second set of nonlinear flow paths.

In some embodiments the nonlinear fluid flow paths of the first set extend in a continuous and non-communicating manner between the first chamber and the third chamber, so that any fluid traveling through one of those nonlinear fluid flow paths is contained along that one of the flow paths between those chambers. Similarly, the nonlinear fluid flow paths of the second set can extend in a continuous and non- communicating manner between the second chamber and the fourth chamber.

In some embodiments, each of the nonlinear fluid flow paths includes at least two linear flow segments that extend in the length-wise direction of the plate assembly. Each of the linear flow segments of the first set can be adjacent to at least one, and sometimes, of the linear flow segments of the second set. Fluid traveling along a linear flow segment of the first set can be in a direction opposite to the direction of the fluid traveling through the adjacent linear flow segment of the second set.

In some embodiments, a first aperture extends through both the first plate and an embossment of the intermediate plate in order to allow for the flow of fluid into or out of the plate assembly through one of the fluid chambers. In some embodiments, a second aperture extends through the first plate in order to allow for the flow of fluid into or out of the plate assembly through another one of the fluid chambers. The second aperture may, but need not, also extend through the intermediate plate. In some, but not all,.

In some embodiments, the first plate is joined to peripheral edges of the intermediate plate at a first plane. The first plane can be located at a point that is approximately midway between the first plate and the second plate in a thickness direction of the plate assembly. Alternatively, the first plane can be located immediately below the outer surface of one of the first and second plates. The first plane can, in some embodiments, be coplanar with one of the inwardly facing surfaces with which crests and troughs of the intermediate plate are in contact. In some such embodiments that one of the first and second plates can be a flat plate without any formed edges.

In some embodiments an embossed area of the first plate defines a second plane that is parallel to the first plane. The inwardly facing surfaces of the first plate with which crests and troughs of the intermediate plate are in contact can be arranged in a third plane that is parallel to and between the first and second planes. In some embodiments the first plate includes a plurality of elongated beads extending from the third plane to the first plane to create a circuitous fluid flow path within the first volume. In some embodiments the circuitous fluid flow path includes multiple parallel arranged and serially connected flow passes, with the first fluid chamber being fluidly connected to the first or the last of the serially connected flow passes.

In some embodiments, the second plate is joined to peripheral edges of the intermediate plate at a fourth plane parallel to the first plane. An embossed area of the second plate defines a fifth plane that is parallel to the first plane. The inwardly facing surfaces of the second plate with which crests and troughs of the intermediate plate are in contact are arranged in a sixth plane that is parallel to and between the fourth and fifth planes. In some embodiments the second plate includes a plurality of elongated beads extending from the sixth plane to the fourth plane to create a circuitous fluid flow path within the second volume. In some embodiments the circuitous fluid flow path includes multiple parallel arranged and serially connected flow passes, with the second fluid chamber being fluidly connected to the first or the last of the serially connected flow passes.

In some embodiments, the plate assembly includes a first, a second, a third, and a fourth fluid chamber. The first fluid chamber can be at least partially arranged in a first embossed area of the first plate and can be in fluid communication with the first volume. The second fluid chamber can be at least partially arranged in a first embossed area of the second plate and can be in fluid communication with the second volume. The third fluid chamber can be at least partially arranged in a second embossed area of the second plate and can be in fluid communication with the second volume. The fourth fluid chamber can be arranged in a second embossed area of the first plate and can be in fluid communication with the first volume. In some embodiments the first and second embossed areas of the first plate and the first and second embossed areas of the second plate are arranged along a common edge of the plate assembly. In some embodiments the first, second, third, and fourth fluid chambers are arranged in a row such that the second and third fluid chambers are between the first and the fourth fluid chambers.

In some such embodiments, the first embossed area of the second plate is arranged directly opposite the first embossed area of the first plate, and the second embossed area of the second plate is arranged directly opposite the second embossed area of the first plate. In some such embodiments, embossments extend from the intermediate plate and engage the embossed areas of the first and second plates in order to provide fluid separation between the first and second fluid chambers and between the third and fourth fluid chambers.

In some embodiments, the plate assembly includes an inlet port for a first fluid, an outlet port for the first fluid, an inlet port for a second fluid, and an outlet port for the second fluid, all joined to the first plate. The inlet port for the first fluid is in fluid communication with either one of the first and fourth fluid chambers, and the outlet port for the first fluid is in fluid communication with the other one of the first and fourth fluid chambers. The inlet port for the second fluid is in fluid communication with either one of the second and third fluid chambers, and the outlet port for the second fluid is in fluid communication with the other one of the second and third fluid chambers. In some such embodiments, the inlet and outlet ports for the second fluid are provided in a single fitting block.

In some embodiments, the plate assembly includes an inlet header and an outlet header that are in fluid communication with the first and second volumes. Flow can be received from the inlet header into one or more of the fluid chambers and can be directed along at least some of the nonlinear fluid flow paths through the plate assembly. The flow can be received from one or more other ones of the fluid chambers into the outlet header. In some embodiments a first flow circuit extending between the inlet header and the outlet header through the first fluid volumes is hydraulically in parallel with a second flow circuit extending between the inlet header and the outlet header through the second fluid volume.

In some embodiments, the plate assembly is one of several such plate assemblies arranged in a stack. The first and second embossed areas of the first plate of the plate assembly engages the first and second embossed areas of the second plate of an adjacent plate assembly in the stack. The first and second embossed areas of the second plate of the plate assembly engages the first and second embossed areas of the first plate of another adjacent plate assembly in the stack.

According to other embodiments of the invention, a heat exchanger includes multiple plate assemblies arranged in a stack. At least some of the plate assemblies have a first, second, and intermediate plate. The intermediate plate is arranged between the first and second plate, and is joined to those plates at peripheral edges to create a sealed periphery of the plate assembly. A first inlet manifold and a first outlet manifold extend through the stack for a first fluid, and are fluidly connected by first fluid flow passages extending through at least some of the plate assemblies. A second inlet manifold and a second outlet manifold extend through the stack for a second fluid, and are fluidly connected by second fluid flow passages extending through at least some of the plate assemblies. Flow channels for a third fluid are arranged between adjacent ones of the plate assemblies.

In some such embodiments, the inlet and outlet manifolds are defined by embossed areas of the first and second plates of the plate assemblies. The embossed areas of adjacent plate assemblies in the stack engage each other to define one or more columns extending through the stack. Some such embodiments have a first column that contains one of the first inlet and outlet manifolds and one of the second inlet and outlet manifold, and a second column that contains the other first and second inlet and outlet manifolds. In some embodiments the first and second columns are arranged at diagonally opposing corners. In other embodiments the first and second columns are arranged along a common side of the heat exchanger.

In some embodiments, the peripheral edges of the first, second, and intermediate plate of each plate assembly are angled upturned edges so that the sealed periphery of each plate assembly is formed by nesting of the plates. Adjacent plate assemblies are similarly nested together.

In some embodiments, at least some of the plate assemblies include a second intermediate plate that is joined to the intermediate plate and to the first and second plates at peripheral edges. The first fluid passages are arranged between the intermediate plates and the first and second plates, and the second fluid flow passages are arranged between the intermediate plates.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings.

A plate assembly <NUM> for a heat exchanger is depicted in <FIG>, and includes three plates (a first plate <NUM>, a second plate <NUM>, and an intermediate plate <NUM> between the first plate <NUM> and the second plate <NUM>) that are joined together at their respective peripheral edges <NUM>. The plates <NUM>, <NUM>, <NUM> are preferably formed from thin metallic sheets by stamping or otherwise forming the sheet material. In some highly preferable embodiments the plates <NUM>, <NUM>, <NUM> are formed from sheets of an aluminum alloy, although other metal materials such as steel, copper, titanium, or others might be equally or more suitable in certain applications. At least some of the plates <NUM>, <NUM>, <NUM> can have a layer of braze material applied to at least some of the plate surfaces, so that metallic joints can be formed at contacting surfaces of the plates. Such a braze material can be applied after forming of the plates, or before forming (as a clad layer on the base material, for example).

A central portion of both the first plate <NUM> and the second plate <NUM> is formed outward from the peripheral sealing surfaces to create an interior space between the plates <NUM>, <NUM>. The intermediate plate <NUM> is provided with corrugations <NUM> in corresponding regions of the plate in order to fill that interior space between the plates <NUM>, <NUM>. The corrugations <NUM> define crests and troughs <NUM>, which are disposed against inwardly facing surfaces <NUM>, <NUM> of the plates <NUM>, <NUM> respectively, and are joined thereto, preferably by brazing.

The intermediate plate <NUM> has a generally rectangular shape, defined by a first pair of spaced apart and parallel edges <NUM>, and a second pair of spaced apart and parallel edges <NUM>, the second pair of edges <NUM> being arranged to be perpendicular to the first pair of edges <NUM>. An edge <NUM> and an edge <NUM> can meet one another at a sharp corner, as shown in <FIG>. Alternatively or in addition, edges <NUM> and <NUM> can be joined by a short edge segment such as the arcuate edge segments <NUM> also depicted in <FIG>.

As best seen in <FIG> and in <FIG>, the corrugations <NUM> are formed into the intermediate plate <NUM> so that the crests and troughs <NUM> are formed on either side of a flat surface <NUM> of the plate. The flat surface <NUM> extends around the outer periphery of the intermediate plate <NUM> to provide the peripheral edge sealing surfaces for the first and second plates <NUM> and <NUM>. Each of the corrugations <NUM> is formed outwardly from the flat surface <NUM>, with multiple long sections of each corrugation <NUM> joined by shorter sections arranged perpendicular to the long sections. In the exemplary embodiment of <FIG>, each of the corrugations includes four long segments aligned parallel to the edges <NUM>, sequentially joined by three short segments aligned parallel to the edges <NUM>, although it should be understood that more or fewer segments can alternatively be employed. When the plates <NUM>, <NUM>, <NUM> are joined to form the plate assembly <NUM>, the intermediate plate <NUM> separates the space between the plates <NUM>, <NUM> into a first volume <NUM> arranged between the first plate <NUM> and the intermediate plate <NUM>, and a second volume <NUM> arranged between the second plate <NUM> and the intermediate plate <NUM>.

The crests and troughs <NUM> in contact with the inwardly facing surfaces <NUM>, <NUM> divide the first and second volumes <NUM>, <NUM> into multiple flow channels for fluid flow through the volumes <NUM>, <NUM>. These flow channels follow the contours of the corrugations <NUM>, and extend in an unbroken and non-communicating manner through the interior space between the plates <NUM> and <NUM>. Elongated beads <NUM> extend from raised central portion of the plates <NUM>, <NUM> to the flat surface <NUM> of the intermediate plate <NUM> between the groupings of the long sections of the corrugations <NUM>, and are generally centrally aligned with the short segments, in order to channel fluid through the flow channels. The intermediate plate <NUM> serves to hydraulically separate the flow channels in the first volume <NUM> from the flow channels in the second volume <NUM>, while still allowing for the transfer of thermal energy by conduction through the relatively thin intermediate plate <NUM>.

The arrangement of the intermediate plate <NUM> within the plate assembly <NUM> allows two separate fluids to be directed to flow through the two volumes <NUM>, <NUM> in isolation from each other, while still enabling beneficial heat exchange between the fluids. Referring to <FIG>, the overall flow arrangement of two fluids through the flow channels is depicted by the arrows <NUM>, <NUM>. The solid arrow <NUM> depicts the flow of a fluid through the flow channels in the first volume <NUM>, while the dashed arrow <NUM> depicts the flow of another fluid through the flow channels in the second volume <NUM>. In the exemplary embodiment of <FIG> the two flows are depicted as flowing in counterflow orientation, but it should be understood by those of skill in the art that for some applications concurrent flow may be beneficial, and can be achieved by reversing the direction of one of the two flows. Individual ones of the flow channels in a given flow volume <NUM>, <NUM> are arranged to be hydraulically in parallel, as will be further described.

Arranged along one of the shorter edges of the plate <NUM> is an embossed area <NUM>, which extends outwardly from the peripheral sealing surfaces by a greater amount than does the formed central portion of the plate. A similar embossed area <NUM> is provided along a corresponding edge of the plate <NUM>. A first pair of circular embossments <NUM> extend from the flat surface <NUM> of the intermediate plate <NUM>, and these circular embossments <NUM> are disposed against and joined to the embossed area <NUM> of the plate <NUM>. A second pair of circular embossments <NUM> extend from the flat surface <NUM> of the intermediate plate <NUM> in a direction opposing that of the first pair of circular embossments <NUM>, and are disposed against and joined to the embossed area <NUM> of the plate <NUM>. The joining of the embossments <NUM>, <NUM> to the embossed areas <NUM>, <NUM> is preferably accomplished by brazing. As best seen in <FIG>, the embossments <NUM>, <NUM> are arranged in a row, with the embossments <NUM> occupying terminal positions in the row and the embossments <NUM> occupying central positions in the row. Circular apertures <NUM> extend through the embossments <NUM>, <NUM>. Similarly, circular apertures <NUM> extend through the embossed area <NUM> of the plate <NUM> in axial alignment with the circular embossments <NUM>, <NUM> of the intermediate plate <NUM>.

With specific reference to <FIG>, the manner by which the individual flow channels of each of the volumes <NUM>, <NUM> are placed hydraulically in parallel will now be described. <FIG> shows one of the circular embossments <NUM> of the intermediate plate <NUM> disposed against the embossed area <NUM> of the plate <NUM>, and one of the circular embossments <NUM> of the intermediate plate <NUM> disposed against the embossed area <NUM> of the plate <NUM>. Two separated fluid chambers are thereby formed within the space provided between the embossed area <NUM> of the plate <NUM> and the embossed area <NUM> of the late <NUM>. A first fluid chamber <NUM> is at least partially bounded by the embossed area <NUM> of the plate <NUM> and the circular embossment <NUM> of the intermediate plate <NUM>, and extends generally the full height of the space provided between the embossed areas <NUM>, <NUM>. Similarly, a second fluid chamber <NUM> is at least partially bounded by the embossed area <NUM> of the plate <NUM> and the circular embossment <NUM> of the intermediate plate <NUM>, and also extends generally the full height of the space provided between the embossed areas <NUM>, <NUM>. The chambers <NUM>, <NUM> are hydraulically separated from one another by the intermediate plate <NUM> itself.

The flat surface <NUM> of the intermediate plate <NUM> extends between the chambers <NUM>, <NUM> of <FIG> and ends of the flow channels defined by the corrugations <NUM>. The presence of the embossed areas <NUM>, <NUM> allow for the flow of fluid between the chambers <NUM>, <NUM> and the flow channels provided on a corresponding side of the intermediate plate <NUM>, so that the fluid chamber <NUM> can serve as a fluid inlet or outlet manifold for fluid passing through the flow channels of the volume <NUM>, and the fluid chamber <NUM> can similarly serve as a fluid inlet or outlet manifold for fluid passing through the flow channels of the volume <NUM>.

As can be inferred from the exploded view of <FIG>, similar chambers <NUM>, <NUM> can be provided by the other circular embossments <NUM> and <NUM> respectively, with those chambers communicating with the opposing ends of the flow channels defined by the corrugations <NUM>. In this manner, two separate fluids can be directed to flow through flow channels of the plate assembly <NUM> (i.e. a first fluid through the volume <NUM> along the path indicated by the arrow <NUM>, and a second fluid through the volume <NUM> along the path indicated by the arrow <NUM>) while remaining hydraulically separate from each other. Direct flow of fluid between the fluid chambers <NUM> or between the fluid chambers <NUM> is undesirable as it would bypass the flow channels provided by the corrugations, and is prevented by forming both the embossed area <NUM> and the embossed area <NUM> in two separated parts, the two parts being separated by a portion of the plate <NUM> or <NUM> that is joined to the flat surface <NUM> of the intermediate plate <NUM> to create a fluid seal.

Fluid can be passed into or out of the plate assembly <NUM> at the fluid chambers <NUM>, <NUM> through the apertures <NUM> provided in the plate <NUM>. In the case where one of the circular embossments <NUM> of the intermediate plate <NUM> is disposed against and joined to the embossed area <NUM> of the plate <NUM>, as is the case for the fluid chamber <NUM> depicted in <FIG>, the fluid must pass through both one of the apertures <NUM> provided at that one of the circular embossments <NUM>, as well as through an aperture <NUM>. In contrast, in the case where one of the circular embossments <NUM> is disposed against and joined to the embossed area <NUM> of the plate <NUM>, as is the case for the fluid chamber <NUM> of <FIG>, the aperture <NUM> is not necessary in that one of the circular embossments <NUM>, and can either be included or dispensed with. It should further be understood that, in some embodiments, it may be preferable for at least some of the apertures <NUM> to be instead provided on the plate <NUM> so that entry or exit of fluid to or from at least some of the chambers <NUM>, <NUM> is provided on the opposing side of the plate assembly <NUM>. In some especially preferable embodiments, the plates <NUM> and <NUM> can be identical plates, or substantially identical with the exception of certain features. As an example, the plates <NUM>, <NUM> can be identical except for the apertures <NUM>, so that the same tooling can be used to form the plates <NUM>, <NUM>.

In the exemplary embodiment of <FIG>, the peripheral edges <NUM> forming the perimeter seal for the plate assembly <NUM> are all generally arranged within a plane that generally coincides with the flat surface <NUM> of the intermediate plate <NUM>. The embossed area <NUM> of the plate <NUM> further defines another plane that is parallel to the plane defined by the peripheral edges <NUM>. Furthermore, the raised central portion of the plate <NUM> wherein the corrugations <NUM> of the intermediate plate <NUM> are located defines yet another plane that is parallel to both the aforementioned planes, and is located therebetween. The embossed area <NUM> and the raised central portion of the plate <NUM> are similarly formed to create planes that are parallel to the plane containing the peripheral edges <NUM>. In this manner, the plane containing the peripheral edges <NUM> is centrally located between the planes defined by the embossed areas <NUM> and <NUM>, and is furthermore centrally located between the planes defined by the raised central portions of the plates <NUM> and <NUM>, with the planes defined by the embossed areas <NUM> and <NUM> being spaced apart by a greater distance than the planes defined by the raised central portions.

In some embodiments, the plate assembly <NUM> can be used to exchange heat between a liquid coolant flowing through one of the fluid volumes <NUM>, <NUM> and a refrigerant flowing through the other of the fluid volumes <NUM>, <NUM>, while simultaneously receiving heat energy through the outwardly facing surfaces of one or both of the plates <NUM>, <NUM>. A plate assembly <NUM> configured for such an embodiment is depicted in <FIG>. Coolant inlet and outlet ports <NUM> are provided at the embossed area <NUM> of the plate <NUM>, and allow for fluid communication between a liquid coolant system (not shown) and the fluid chambers <NUM>. Liquid coolant is received through one of the coolant ports <NUM> into one of the fluid chambers <NUM> and is directed through the flow channels that extend through the volume <NUM> before being received into the other fluid chamber <NUM> and removed from the plate assembly <NUM> through the other coolant port <NUM>. Simultaneously, a flow of refrigerant is directed through the volume <NUM> of the plate assembly <NUM> through the use of a refrigerant fitting block <NUM> that is also provided at the embossed area <NUM> of the plate <NUM>. The fitting block <NUM> includes refrigerant inlet and outlet ports <NUM>, each of which are in fluid communication with one of the fluid chambers <NUM>. A flow of refrigerant is received into one of the refrigerant ports <NUM> from a refrigerant system (not shown) in a liquid state or a low vapor quality two-phase state, and is directed through the flow channels that extend through the volume <NUM>. The refrigerant is subsequently received into the other fluid chamber <NUM>, preferably in a superheated vapor or high vapor quality two-phase state, and is returned to the refrigerant system through the other refrigerant port <NUM> provided in the fitting block <NUM>.

The plate assembly <NUM> of <FIG> can find particular utility as a chiller plate for cooling a heat-producing solid device such as, for example, a battery. Such a device can be disposed directly against the outwardly facing planar surface <NUM> of the plate <NUM>, so that heat generated by the device is efficiently transferred through the plate <NUM> into the fluids passing through the plate assembly <NUM>. The present invention provides the capability to maintain a substantially uniform temperature profile over the planar surface <NUM>, thereby improving both the performance and durability of the device.

By combining two separate fluid flows within a single plate assembly <NUM>, the undesirable aspects of both single-phase liquid cooling and two-phase refrigerant cooling can be avoided. A liquid coolant of a lower flow rate can be used as the fluid circulating through the volume <NUM> in order to receive heat input through the surface <NUM>, while simultaneously rejecting heat to a lower-temperature refrigerant stream circulating through the volume <NUM>. The rejection of heat from the liquid coolant while still within the plate assembly <NUM> enables the flow of liquid coolant to remain within a desirable temperature range throughout the flow path <NUM>, without requiring a high mass flow rate. In addition, the presence of the liquid coolant as an intermediary fluid between the heat source disposed against the surface <NUM> and the flow of refrigerant along the flow path <NUM> provides increased thermal inertia over a refrigerant-only cooling system.

In some embodiments, a system including multiple such battery cooling plates <NUM> can be implemented in order to cool multiple batteries. It may be especially desirable to operate such a system so that the rate of heat transfer into the coolant through the surface <NUM> is approximately equal to the rate of heat transfer from the coolant to the refrigerant, so that the liquid coolant is removed from the plate assembly <NUM> at a temperature that is approximately equivalent to the temperature at which it entered the plate assembly <NUM>. Such operation allows for multiple plate assemblies <NUM> to be arranged hydraulically in series along the liquid coolant circuit while still maintaining a uniform temperature for each of the batteries.

An alternative embodiment of the plate assembly <NUM> is depicted in exploded view in <FIG>, and is intended to be used with only a single fluid. In the exemplary embodiment of <FIG>, the single cooling fluid is a liquid coolant, and a pair of coolant ports <NUM> are provided at two adjacent apertures <NUM> of the top plate <NUM>. It should be appreciated that in other embodiments the single cooling fluid could be a refrigerant, and the fitting block <NUM> having two refrigerant ports <NUM> could be provided at the same location in place of the coolant ports <NUM>.

In the embodiment of <FIG>, the cooling fluid is introduced into the plate assembly <NUM> through one of the coolant ports <NUM>, and is routed through one of the volumes <NUM>, <NUM> in a similar manner to that described previously with respect to the embodiment of <FIG>. However, the intermediate plate <NUM> is only provided with the circular embossments <NUM>, <NUM> in those locations that correspond to the locations of the coolant ports <NUM>. Apertures <NUM> are provided in the planar surface <NUM> of the intermediate plate <NUM> at the two additional locations where embossments <NUM>, <NUM> were provided in the embodiment of <FIG>, and these two apertures <NUM> allow for the coolant to pass from one side of the intermediate plate <NUM> to the other side of the intermediate plate. Accordingly, the coolant will be routed along the flow passages extending through one of the volumes <NUM>, <NUM> and, subsequently, through the flow passages extending through the other one of the volumes <NUM>, <NUM>. The coolant flow is thereby placed in counter-current flow orientation to itself as it passes along the opposite sides of the plate, so that heat can be transferred through the intermediate plate <NUM> between the coolant flow near the inlet port <NUM> and coolant flow near the outlet port <NUM>. Such heat transfer can smooth out the temperature profile of the coolant flow passing through plate assembly <NUM>, allowing for a more uniform fluid temperature.

In yet another embodiment, illustrated in <FIG>, a plate assembly <NUM> specifically adapted for use as a battery cooling plate heat exchanger uses a single cooling fluid to provide one or more chilled outer surfaces to which a battery or other heat producing source can be attached, so that the temperature of the battery or other heat producing source can be maintained through the removal of heat energy into the cooling fluid. Unlike the plate assembly of <FIG>, the cooling fluid in the plate assembly <NUM> makes only a single pass through the plate assembly between an inlet manifold and an outlet manifold.

The plate assembly <NUM> includes a first plate <NUM>, a second plate <NUM>, and an intermediate plate <NUM> arranged therebetween. The three plates <NUM>, <NUM>, and <NUM> generally correspond to the plates <NUM>, <NUM>, and <NUM>, respectively of the previously described plate assembly <NUM>. Each of the plates <NUM>, <NUM>, <NUM> is of a generally rectangular shape of equal footprint, and the plates are joined together along peripheral edges <NUM> (as best seen in <FIG>) in order to seal the plate assembly <NUM>. In similar fashion as was described with respect to the intermediate plate <NUM>, the intermediate plate <NUM> is provided with corrugation <NUM> that create crests and troughs <NUM>. Theses crests and troughs <NUM> are disposed against inwardly facing surfaces <NUM>, <NUM> of the plates <NUM>, <NUM> respectively, and are joined thereto, preferably by brazing.

The intermediate plate <NUM> is provided with a planar peripheral edge surface <NUM> that lies within a common plane as the crests <NUM> disposed against the plate <NUM>, so that the edge surface <NUM> is disposed against the inwardly facing surface <NUM> along the outer periphery <NUM>. Such a design can provide certain advantages over the previously described embodiment of the plate assembly <NUM>, wherein the joined edges were located within a central plane of the plate assembly along a thickness dimension of the plate assembly, by providing a continuous outwardly facing planar surface on the plate <NUM>. Such a continuous planar surface can provide advantages in the mounting of a heat producing source such as a battery to that outwardly facing surface. However, in some embodiments it may be more preferable to adapt the plate assembly <NUM> to have the centrally located edge joints shown in <FIG>. Likewise, the plate assembly <NUM> described earlier can alternatively be adapted to use the peripheral joint shown in <FIG>.

As best seen in the exploded view of <FIG>, the plate <NUM> is provided with a peripheral planar edge surface <NUM>, which is joined to the intermediate plate <NUM> along the periphery <NUM>, and a central dished region <NUM>. The central dished region <NUM> forms a space between the inwardly facing surfaces <NUM> and <NUM>, within which the corrugations <NUM> of the intermediate plate <NUM> are located. In a similar fashion to that described previously with respect to the corrugations <NUM> of the intermediate plate <NUM>, the corrugations <NUM> of the intermediate plate <NUM> define multiple fluid flow channels that follow the contours of the corrugations <NUM> and extend in an unbroken and non-communicating manner through the interior space between the plates <NUM> and <NUM>. As can be seen in the section view of <FIG>, flow channels <NUM> are provided between the intermediate plate <NUM> and the plate <NUM>, and flow channels <NUM> are provided between the intermediate plate <NUM> and the plate <NUM>.

The plate assembly <NUM> extends in what will be referred to as a lengthwise direction, indicated in <FIG> by the double-ended arrow <NUM>. In the exemplary embodiment the length-wise direction <NUM> is the longer direction of the plate assembly <NUM>, but it should be understood that in some embodiments the length-wise direction may be the shorter direction of the plate assembly. A fluid manifolding area <NUM> is provided at one end, in the length- wise direction, of the plate assembly <NUM>. The fluid manifolding area <NUM> is characterized by an absence of corrugations <NUM> in the intermediate plate <NUM>. As can be best seen in <FIG>, the intermediate plate <NUM> is provided with a generally planar wall <NUM> in the manifolding area, with that planar wall <NUM> being located approximately midway between the inwardly facing surfaces <NUM> and <NUM> in the thickness direction of the plate assembly (the thickness direction being indicated in <FIG> by the double-ended arrow <NUM>).

The fluid manifold area <NUM> includes four separate chambers. Two chambers <NUM> and <NUM> are arranged between the planar wall <NUM> and the plate <NUM>, while two chambers <NUM> and <NUM> are arranged between the planar wall <NUM> and the plate <NUM>. A bead <NUM> is formed into the dished region <NUM> of the plate <NUM>, and extends in the lengthwise direction <NUM> from an edge of the plate <NUM> so that the bead extends through the fluid manifolding region <NUM>. The plates <NUM>, <NUM>, and <NUM> are joined together at the location of the bead <NUM>, so that the fluid manifolding region <NUM> is separated into two halves, with the chambers <NUM> and <NUM> located on one side of the bead <NUM> and the chambers <NUM> and <NUM> located on the other side. The joint at the bead <NUM> hydraulically separates the chamber <NUM> from the chamber <NUM>, and the chamber <NUM> from the chamber <NUM>. A corresponding bead <NUM> is provided in the intermediate plate <NUM> in order to allow for the creation of the joint. Alternatively, the corresponding bead could be provided in the plate <NUM>.

A fluid inlet header <NUM> and a fluid outlet header <NUM> are joined to the plate <NUM> within the fluid manifolding area <NUM>. Both of the headers <NUM>, <NUM> are depicted, in the exemplary embodiment, as cylindrical headers, although other shapes such as, by way of example, D-shaped headers could be used instead. An inlet port <NUM> is joined to the inlet header <NUM> in order to provide the cooling fluid to the plate assembly <NUM>, and an outlet port <NUM> is joined to the outlet header <NUM> in order to remove the cooling fluid from the plate assembly <NUM>.

Two sets of apertures extending from the inlet header <NUM> provide fluid communication between the inlet header <NUM> and the fluid chambers <NUM> and <NUM>. A first set of apertures <NUM> are aligned with the header <NUM> on the side of the bead <NUM> that corresponds with the location of the chamber <NUM>, while a second set of apertures <NUM> are aligned with the header <NUM> on the side of the bead <NUM> that corresponds with the location of the chamber <NUM>. Similarly, sets of apertures <NUM> and <NUM> provide fluid communication between the outlet header <NUM> and the fluid chambers <NUM> and <NUM>, respectively. As a result, the chambers <NUM> and <NUM> are a first and a second inlet chamber for fluid flowing through the plate assembly <NUM>, and the chambers <NUM> and <NUM> are a first and a second outlet chamber for fluid flowing through the plate assembly <NUM>. The apertures are arranged so that the first inlet chamber <NUM> overlaps with the second outlet chamber <NUM> in a thickness direction <NUM> of the plate assembly, and the second inlet chamber <NUM> overlaps with the first outlet chamber <NUM> in the thickness direction <NUM>.

The plate <NUM> is provided with collar flanges <NUM> surrounding the apertures <NUM><NUM>, <NUM>, and <NUM> to provide for easy positioning of the headers <NUM> and <NUM> onto the plate <NUM>. Embossments <NUM> extend towards the plate <NUM> from the planar wall <NUM> of the intermediate plate <NUM> at the locations of the apertures <NUM> and <NUM>, with the apertures extending through those embossments. The embossments <NUM> are disposed against the inwardly facing surface <NUM> of the plate <NUM> and are joined thereto, creating fluid seals. The seals at the apertures <NUM> prevent any leakage of fluid the header <NUM> and the chamber <NUM>, which is located between the plate <NUM> and the chamber <NUM>. In a similar way, the seals at the apertures <NUM> prevent any leakage of fluid between the header <NUM> and the chamber <NUM>, which is located between the plate <NUM> and the chamber <NUM>.

Additional embossments <NUM> are optionally provided in the fluid manifold region <NUM>. The dimples <NUM>, if present, extend from the planar wall <NUM> towards the plate <NUM>, and engage with the inwardly facing surface <NUM> of that plate in order to provide structural support in the un-corrugated manifold region <NUM>. The locations of the embossments <NUM> can be selected to coincide with the locations of the apertures <NUM> and <NUM> in order to improve the flow of fluid through the apertures.

During operation of the battery cooling plate heat exchanger <NUM>, a flow of cooling fluid (for example, a liquid coolant or a refrigerant) is received into the inlet header <NUM> through the inlet port <NUM>. The cooling fluid is distributed, preferably in approximately equal amounts, into the chambers <NUM> and <NUM> through the apertures <NUM> and <NUM>, respectively. The chambers <NUM> and <NUM> thereby function as a first and a second inlet chamber for the cooling fluid. The portion of the cooling fluid that is received into the first inlet chamber <NUM> is distributed among the set of flow channels <NUM>, and flows in a U- shaped flow pattern (indicated by the arrow <NUM> in <FIG>) to the chamber <NUM>. Similarly, the portion of the cooling fluid that is received into the second inlet chamber <NUM> is distributed among the set of flow channels <NUM>, and flows in a U-shaped flow pattern (indicated by the arrow <NUM> in <FIG>) to the chamber <NUM>. The chambers <NUM> and <NUM> thereby function as a first and a second outlet chamber for the cooling fluid. The cooling fluid is received into the outlet header <NUM> from the outlet chambers <NUM> and <NUM> through the apertures <NUM> and <NUM>, respectively, and is subsequently removed from the header <NUM> through the outlet port <NUM>. The first inlet chamber <NUM>, first outlet chamber <NUM>, and flow paths <NUM> together define a first fluid volume within the battery plate heat exchanger. Similarly, the second inlet chamber <NUM>, second outlet chamber <NUM>, and flow paths <NUM> together define a second fluid volume within the battery plate heat exchanger. The first and second fluid volumes are hydraulically separated from one another between the plates <NUM> and <NUM>. The first and second fluid volumes provide hydraulically parallel paths for fluid to pass from the inlet header <NUM> to the outlet header <NUM>.

As the cooling fluid passes through the flow channels <NUM> and <NUM>, heat energy that is received through one or both of the plates <NUM> and <NUM> is transferred by convection to the cooling fluid, thereby heating the cooling fluid. It should be observed that the two U- shaped flow paths <NUM> and <NUM> are oriented so that the flows along those paths are in counterflow orientation. It should be further observed that, due to the nature of the corrugations <NUM>, flow channels <NUM> and <NUM> are arranged in alternating fashion.

While <FIG> depicts an embodiment that uses a single U-shaped flow path on each side of the intermediate plate <NUM>, it should be understood that in some alternative embodiments the flow paths <NUM> and <NUM> can include additional U-shaped passes. By way of example, the flow paths <NUM> and <NUM> (shown in <FIG>) which each have two consecutive U-shaped passes could be substituted into the embodiment described in <FIG> in order to improve the distribution of fluid among the multiple individual flow channels. In addition, it should be understood that the previously described embodiments of a battery cooling plate having such double U-shaped flow passages could be modified to have the single U-shaped flow passages of <FIG>, for example to reduce the pressure drop incurred by the fluid as it passes through the plate assembly.

Orienting the flow paths <NUM> and <NUM> to be in a counterflow orientation to one another provides certain benefits, especially when the plate assembly <NUM> is to be used as a battery cooling plate heat exchanger. The corrugations <NUM> of the intermediate plate <NUM> are arranged such that each of the multiple nonlinear flow paths <NUM> and <NUM> include two linear flow segments <NUM> that extend in the lengthwise direction <NUM>, one extending from an inlet chamber <NUM> or <NUM> and one extending to an outlet chamber <NUM> or <NUM>. As previously indicated, two such linear flow segments is a minimum, since the flow paths <NUM> and <NUM> can include multiple U-shaped segments. The linear flow segments <NUM> of each flow path can be joined by an additional linear flow section extending in a direction perpendicular to the lengthwise direction <NUM> (i.e. a widthwise direction of the plate heat exchanger <NUM>), as shown in the embodiment of <FIG>, although in other alternative embodiments the U-shaped flow configuration can be achieved by, for example, nonlinear connecting segments such as arcuate segments, or by piecewise linear segments arranged at varying angles to the lengthwise direction <NUM>, or others.

As can be seen in the section view of <FIG>, which is taken through some of the linear segments <NUM>, that each of the linear flow segments <NUM> of a flow path <NUM> is adjacent to a linear flow segment <NUM> of a flow path <NUM>, and vice versa. In all cases except for the end flow channels (such as that one of flow paths <NUM> arranged at the far right hand side of <FIG>) each linear flow segment <NUM> is sandwiched between two linear flow segments <NUM> of the other flow path. Due to the counterflow orientation of the overall flow paths <NUM> and <NUM>, the fluid traveling through those linear flow segments <NUM> extending from the inlet chamber <NUM> will be directly adjacent to fluid traveling through those linear flow segments <NUM> extending to the outlet chamber <NUM>. Similarly, the fluid traveling through those linear flow segments <NUM> extending from the inlet chamber <NUM> will be directly adjacent to fluid traveling through those linear flow segments <NUM> extending to the outlet chamber <NUM>. Since the fluid is continuously heated as it passes along the flow channels <NUM> and <NUM> by the battery mounted to the battery plate heat exchanger, the result is that the coldest fluid (i.e. the fluid in the channels <NUM> immediately downstream of the inlet chamber <NUM> and the fluid in the channels <NUM> immediately downstream of the inlet chamber <NUM>) is interlaced with the hottest fluid (i.e. the fluid in the channels <NUM> immediately upstream of the outlet chamber <NUM> and the fluid in the channels <NUM> immediately upstream of the inlet chamber <NUM>). This has the benefit of providing a more uniform temperature distribution on the outer surfaces of the plate <NUM> and/or the plate <NUM> to which the battery is mounted. Maintaining a more uniform temperature in the batteries is known to be beneficial to improved battery performance and life.

<FIG> depicts a heat exchanger <NUM> which is not covered by the claims and is constructed using a stack <NUM> of the plate assemblies <NUM>. A top plate <NUM> having a footprint that extends beyond that of the stack <NUM> can be provided at an end of the stack <NUM> to allow for mounting of the heat exchanger <NUM> into an enclosure. By way of example, the stack <NUM> can be inserted through an open face of a housing so that the top plate <NUM> closes off the insertion opening, and the heat exchanger <NUM> can be secured to the housing by way of fastening locations <NUM> provided along the periphery of the top plate <NUM>. Coolant ports <NUM> and a refrigerant fitting block <NUM> having refrigerant ports <NUM> can be mounted directly to top plate <NUM> to allow for fluid connection of the heat exchanger <NUM> within a heat transfer system.

The plate assemblies <NUM> of the stack <NUM> are arranged so that the embossed areas <NUM> of one plate assembly <NUM> within the stack <NUM> abut and are joined to the embossed areas <NUM> of an adjacent plate assembly <NUM>. In this manner, the aligned fluid chambers <NUM>, <NUM> can be connected by the apertures <NUM> and <NUM> to form fluid manifolds extending along the height of the stack <NUM>. Coolant and/or refrigerant entering the heat exchanger <NUM> through one of the coolant ports <NUM> and/or refrigerant ports <NUM> can be distributed to the flow paths <NUM>, <NUM> within the individual plate assemblies <NUM> by way of these fluid manifolds. Similarly, the fluids can be collected from the flow paths into the fluid manifolds corresponding to the outlet ports to enable the removal of the fluid from the heat exchanger <NUM>. Such a complete stack <NUM> can preferably be formed in a single furnace brazing operation.

Serpentine fins <NUM> can be provided within the spaces between adjacent planar surfaces <NUM> of the plate assemblies <NUM>, and can be bonded to those planar surfaces <NUM> to provided extended heat transfer surfaces for a fluid passing through those spaces. By way of example, such a heat exchanger <NUM> can provide particular utility for cooling a flow of heated air passing through the serpentine fins. Heat can be transferred to both a flow of coolant and to a flow of refrigerant passing through the heat exchanger <NUM>. As discussed previously, by transferring heat to the two streams simultaneously, the undesirable aspects of both single-phase liquid cooling and two-phase refrigerant cooling can be avoided. In some alternative embodiments, the stack <NUM> can be constructed of the plate assemblies of the embodiment of <FIG>, so that a single fluid is used to cool the flow of air through the fins <NUM>. It should be appreciated that the direction of heat transfer can be reversed so that the heat exchanger <NUM> is used to heat a flow of fluid passing through the fins <NUM>, rather than cooling it.

It may be desirable, in some alternative versions of the heat exchanger <NUM>, for one of the cooling fluids to pass through some, but not all, of the plate assemblies. This can be accomplished by removing the intermediate plate <NUM> from some of the plate assemblies, and instead placing spacer disks between the embossed areas <NUM>, <NUM> in places corresponding to either the embossments <NUM> or the embossments <NUM>, depending on the fluid that is to be precluded from flowing through the plate assembly. The spacer disks provide for fluid continuity through the fluid manifolds without allowing that one of the fluids to pass through the heat exchange area of the plate assembly.

In some alternative embodiments, a plate assembly <NUM> includes a pair of intermediate plates <NUM> arranged between the plates <NUM> and <NUM>, as depicted in <FIG>. Crests and troughs <NUM> of a first one of the intermediate plates <NUM> (identified as 4a in <FIG>) are alternatingly joined to the inwardly facing surface <NUM> of the plate <NUM> and the other one of the intermediate plates <NUM> (identified as 4b in <FIG>). In a similar manner, crests and troughs <NUM> of the intermediate plate 4b are alternatingly joined to the inwardly facing surface <NUM> of the plate <NUM> and the intermediate plate 4a. This provides a fluid volume <NUM> between the intermediate plates 4a, 4b through which one of the flow paths <NUM>, <NUM> can extend, while the other one of the flow paths can extend through the volumes <NUM> created between the intermediate plates and the surfaces <NUM> and <NUM>. Heat can thus be transferred from a heat source provided on external surfaces of both of the plates <NUM> and <NUM> to the fluid passing through the volume <NUM>, and from that fluid to the fluid passing through the volume <NUM>, or vice-versa.

Another heat exchanger <NUM> constructed as a stacked-plate style heat exchanger, which is not covered by the claims, is shown in <FIG>. The heat exchanger <NUM> includes multiple plate assemblies that are stacked together in a nested relationship to form a stack <NUM>. As best seen in the cross-sectional detail views of <FIG>, each of the plate assemblies includes a first formed plate <NUM>', a second formed plate <NUM>', and an intermediate plate <NUM>'. The plates <NUM>', <NUM>' and <NUM>' are generally similar to the previously described plates <NUM>, <NUM> and <NUM> respectively, but differ in that each of the plates <NUM>', <NUM>' and <NUM>' are provided with an upturned angled edge extending along the plate periphery. The upturned edges cooperate to allow the plates of each plate assembly to nest together along the peripheral edges, allowing for a self-stacking arrangement of the plates within a plate assembly, and also allowing for a similar self-stacking arrangement of adjacent ones of the plate assemblies within the stack <NUM>.

The heat exchanger <NUM> is especially well-suited for enabling the exchange of heat between a liquid coolant flow and two separate refrigerant flows. The two separate refrigerant flows can each be directed through the plate assemblies, with a first one of the refrigerant flows passing along the flow channels provided on one side of the intermediate plates <NUM> and a second one of the refrigerant flows passing along the flow channels provided on the opposing side of the intermediate plates <NUM>. In a similar manner to that described previously with respect to the earlier embodiments, embossed areas <NUM> are formed into the plates <NUM>' and embossed areas <NUM> are formed into the plates <NUM>'. However, instead of being arranged along a common edge of the heat exchanger <NUM>, the embossed areas <NUM> and <NUM> are arranged in two diagonally opposing corners of the heat exchanger.

Each adjacent pair of plate assemblies, in addition to being joined together at the nested peripheral edges of the plate assemblies, is joined by the embossed area <NUM> of one plate assembly directly abutting and bonded to the embossed area <NUM> of the other plate assembly. Embossments <NUM> and <NUM> are again provided in opposing directions on each of the intermediate plates <NUM>', with the embossments <NUM> disposed against and bonded to the embossed areas <NUM> and with the embossments <NUM> disposed against and bonded to the embossed areas <NUM>. Apertures are again provided in the embossments <NUM> and <NUM> and in the embossed areas <NUM> and <NUM>, thereby forming a fluid manifold <NUM> for one of the two refrigerant flows and a fluid manifold <NUM> for the other of the two refrigerant flows at each of the two diagonally opposing corners of the heat exchanger <NUM> to distribute the refrigerant to and from the flow passages within the plate assemblies.

Connection of the refrigerant flow paths to one or more refrigerant systems is accomplished by way of a first refrigerant fitting block 25A affixed to one end of the heat exchanger <NUM> in the stacking direction and a second refrigerant block 25B affixed to the opposing end of the heat exchanger <NUM> in the stacking direction. The fitting block 25A includes two refrigerant ports 24A for the first one of the refrigerant flows, with one of the ports 24A serving as a refrigerant inlet port to provide that first flow of refrigerant to the heat exchanger <NUM>, and the other serving as a refrigerant outlet port to remove that first flow of refrigerant from the heat exchanger <NUM>. Similarly, the fitting block 25B includes two refrigerant ports 24B for the second one of the refrigerant flows, with one of the ports 24B serving as a refrigerant inlet port to provide that second flow of refrigerant to the heat exchanger <NUM>, and the other serving as a refrigerant outlet port to remove that second flow of refrigerant from the heat exchanger <NUM>.

Each of the fitting blocks 25A, B can preferably be arranged at one of the two opposing corners corresponding to the locations of the fluid manifolds <NUM>, <NUM>. This conveniently allows for one of the two ports 24A to be connected to either the fluid manifold <NUM> or the fluid manifold <NUM> at its corresponding corner, with the other of the two ports 24A connected to the corresponding port <NUM> or <NUM> at the opposing corner by way of a transfer channel <NUM> provided at the end of the heat exchanger <NUM>. Such a transfer channel <NUM> can be conveniently provided by a deformation in an end plate <NUM> that is provided at the top end of the stack <NUM>. Similarly, one of the two ports 24B can be connected to either the fluid manifold <NUM> or the fluid manifold <NUM> at its corresponding corner, with the other of the two ports 24B connected to the corresponding port <NUM> or <NUM> at the opposing corner by way of a similar transfer channel provided within a base plate <NUM> provided at the bottom of the stack <NUM>. The fitting blocks <NUM> A and 25B can be arranged at one common corner of the heat exchanger <NUM>, or at opposing corners.

Fluid manifolds <NUM> for the flow of coolant can be provided at the remaining two diagonally opposing corners <NUM>, and can be connected by way of coolant passages arranged between adjacent ones of the plate assemblies. Turbulating inserts for the coolant (generally represented in the detail cross-sectional view of <FIG> by the reference number <NUM>) can be provided between the plate assemblies, with appropriate cut-outs at the corners to accommodate the embossed areas <NUM> and <NUM>. As shown in <FIG>, the fluid manifolds <NUM> for the coolant can be formed by providing apertures in the inserts <NUM> as well as in the plates <NUM>', <NUM>' and <NUM>', with the surfaces of the plates in each plate assembly joined together at the periphery of those apertures to seal the coolant manifolds from the internal volumes of the plate assemblies <NUM>. Inlet and outlet ports for the flow of coolant are not shown, but can be easily provided in either the base plate <NUM>, the top plate <NUM>, or both.

In a similar manner to that previously described with reference to <FIG>, it is possible for the intermediate plate <NUM>' to be provided within fewer than all of the plate assemblies, with suitable spacers added within those of the assemblies lacking such an intermediate plate <NUM>' to provide for fluid integrity of the fluid manifolds <NUM> or <NUM> through that plate assembly.

Claim 1:
A battery cooling plate heat exchanger, comprising:
exactly one first plate (<NUM>);
exactly one second plate (<NUM>);
exactly one intermediate plate (<NUM>) arranged between the first and the second plate (<NUM>, <NUM>) and joined thereto at peripheral edges to create a sealed periphery,
the intermediate plate (<NUM>) having corrugations (<NUM>) with crests and troughs (<NUM>) in contact with inwardly facing surfaces (<NUM>, <NUM>) of the first and the second plate (<NUM>, <NUM>);
a fluid manifolding area (<NUM>) arranged at an end of the battery cooling plate heat exchanger in a lengthwise direction of the battery cooling plate heat exchanger;
a first inlet chamber (<NUM>), first outlet chamber (<NUM>), second inlet chamber (<NUM>), and second outlet chamber (<NUM>) arranged within the fluid manifolding area (<NUM>);
a first plurality of nonlinear fluid flow paths (<NUM>) arranged between the intermediate plate (<NUM>) and the first plate (<NUM>) and providing fluid connections between the first inlet chamber (<NUM>) and the first outlet chamber (<NUM>); and
a second plurality of nonlinear fluid flow paths (<NUM>) arranged between the intermediate plate (<NUM>) and the second plate (<NUM>) and providing fluid connections between the second inlet chamber (<NUM>) and the second outlet chamber (<NUM>).