Mal-Distribution in Plate Fin Heat Exchanger

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/654,878, filed May 31, 2024, the entirety of which is herein incorporated by reference.

The disclosure relates to a heat exchanger, and more particularly to a plate heat exchanger with improved flow distribution.

Conventional air-conditioning and thermal management systems include a compressor and multiple heat exchangers. One type of heat exchanger commonly used in the thermal management systems is a plate heat exchanger. Plate heat exchangers are typically comprised of stacked plates in which two working fluids, for example, a refrigerant and a coolant, flows through intermediate spaces between adjacent plates, wherein the refrigerant flows from a first side of the plate heat exchanger to the opposite second side of the plate heat exchanger, while the coolant flows parallel to the refrigerant or in the opposite direction from the same end but opposite side or the opposite end to the first end of the plate heat exchanger. The length of the flow channels in the plate heat exchanger corresponds essentially to the length of the plate heat exchanger from the first end to the second end. The outer dimensions of the plate heat exchanger and the position of the connections of the plate heat exchanger are therefore defining the length of the flow channels in the plate heat exchanger.

Prior art plate heat exchangers, however, are vulnerable to single and multiple-phase flow maldistribution of the working fluids. This phenomenon degrades an effective heat transfer across the plate heat exchanger, especially in parallel counter flow plate heat exchangers, which negatively impacts an overall thermal management system performance.

Accordingly, it is desirable to develop a plate heat exchanger with improved flow distribution using unique and efficient flow circuitry to mitigate against maldistribution of the working fluids therein, which optimizes a performance and efficiency of the heat exchanger, while minimizing complexity thereof.

In concordance and agreement with the presently described subject matter, a plate heat exchanger with improved flow distribution using unique and efficient flow circuitry to mitigate against maldistribution of the working fluids therein, which optimizes a performance and efficiency of the heat exchanger, while minimizing complexity thereof, has been newly designed.

An object of the heat exchanger of the present disclosure is to change the flow of the working fluids internally without changing a location of external inlet and outlet ports.

Another object of the heat exchanger of present disclosure is to force the flow of at least one of the working fluids (e.g., a refrigerant) to more effectively utilize a heat transfer surface area, improving the performance of the heat exchanger.

In one embodiment, a thermal energy transfer device for a plate heat exchanger, comprises: a sheet of material; an inflow opening formed in the sheet, the inflow opening configured to receive a flow of a fluid therein; an outflow opening formed in the sheet, the outflow opening configured to receive the flow of the fluid therein; a plurality of flow channels formed in the sheet in fluid communication with the inflow opening and the outflow opening; and a flow diverter formed in the sheet between the inflow opening and the outflow opening, wherein the flow diverter is formed at an angle to a direction of the flow of the fluid from the inflow opening to the outflow opening.

In another embodiment, a heat exchanger, comprises: a plurality of first plates; and a plurality of second plates alternatingly arranged with the first plates to form at least one flow path for at least one fluid; and at least one thermal energy transfer device disposed in the at least one flow path, wherein the at least one thermal energy transfer device, comprises: a sheet of material; an inflow opening formed in the sheet, the inflow opening configured to receive a flow of the at least one fluid therein; an outflow opening formed in the sheet, the outflow opening configured to receive the flow of the at least one fluid therein; a plurality of flow channels formed in the sheet in fluid communication with the inflow opening and the outflow opening; and a flow diverter formed in the sheet between the inflow opening and the outflow opening, wherein the flow diverter is formed at an angle to a direction of the flow of the at least one fluid from the inflow opening to the outflow opening.

In yet another embodiment, a heat exchanger, comprises: a plurality of first plates; and a plurality of second plates alternatingly arranged with the first plates to form at least one first flow path for a first fluid and at least one second flow path for a second fluid, wherein the at least one first flow path is substantially parallel to the at least one second flow path; at least one first thermal energy transfer device disposed in the at least one first flow path for the first fluid; and at least one second thermal energy transfer device disposed in the at least one second flow path for the second fluid, wherein one or more of the first and second thermal energy transfer devices, comprises: a sheet of material; an inflow opening formed in the sheet, the inflow opening configured to receive a flow of the first fluid or the second fluid therein; an outflow opening formed in the sheet, the outflow opening configured to receive the flow of the first fluid or the second fluid therein; a plurality of flow channels formed in the sheet in fluid communication with the inflow opening and the outflow opening; and a flow diverter formed in the sheet between the inflow opening and the outflow opening, wherein the flow diverter is formed at an angle to a direction of the flow of the first fluid or the second fluid from the inflow opening to the outflow opening.

As aspects of some embodiments, one or more of the flow channels is formed at an angle to the direction of the flow of the fluid from the inflow opening to the outflow opening.

As aspects of some embodiments, one or more of the flow channels is a vertical flow channel or a horizontal flow channel.

As aspects of some embodiments, the flow diverter is formed by deforming at least a portion of one or more of the flow channels.

As aspects of some embodiments, one or more of the flow channels extends from a longitudinal edge of the sheet to an opposite longitudinal edge of the sheet.

As aspects of some embodiments, one or more of the flow channels extends from a lateral edge of the sheet to an opposite lateral edge of the sheet.

As aspects of some embodiments, one or more of the flow channels is fluidly connected to one or more adjacent flow channels by one or more fluid passageways formed in the sheet.

As aspects of some embodiments, the sheet is a stamped sheet formed from a metal material.

As aspects of some embodiments, the flow diverter is formed in the sheet more proximate the inflow opening than the outflow opening.

As aspects of some embodiments, the flow diverter is formed in the sheet more proximate the outflow opening than the inflow opening.

As aspects of some embodiments, the flow diverter is formed in a center portion of the sheet.

As aspects of some embodiments, the flow diverter is formed substantially perpendicular to the direction of the flow of the fluid from the inflow opening to the outflow opening.

As aspects of some embodiments, the flow diverter extends vertically from a longitudinal edge portion of the sheet to a center portion of the sheet.

As aspects of some embodiments, the flow diverter extends horizontally from a lateral edge portion of the sheet to a center portion of the sheet.

As aspects of some embodiments, the flow diverter extends from a longitudinal edge portion of the sheet towards an opposite longitudinal edge portion of the sheet.

As aspects of some embodiments, the flow diverter extends from a lateral edge portion of the sheet towards an opposite lateral edge portion of the sheet.

As aspects of some embodiments, the flow diverter extends vertically or horizontally across at least half of the sheet.

As aspects of some embodiments, the flow diverter extends vertically or horizontally across less than half of the sheet.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more present disclosures, and is not intended to limit the scope, application, or uses of any specific present disclosure claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps may be different in various embodiments. “A” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” and/or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and/or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

All documents, including patents, patent applications, and scientific literature cited in this detailed description are incorporated herein by reference, unless otherwise expressly indicated. Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls.

Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

As referred to herein, all compositional percentages are by weight of the total composition, unless otherwise specified. Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

illustrates a thermal management systemgenerally. As depicted, the thermal management systemmay include one or more plate heat exchangersaccording to embodiments of the present disclosure and described hereinafter. In some embodiments, the heat exchangersmay perform as an evaporator and/or a condenser. The heat exchangersmay be fluidly connected and/or in fluid communication with a first circuitfor a first fluid (e.g., a refrigerant) and a second circuitfor a second fluid (e.g. a coolant). It is understood that each of the second circuitsshown may be separate and distinct circuits for the second fluid. It is also understood that the second fluid may be different or the same for each of the heat exchangers. It should be appreciated that each of the fluids may have any desired pressure. For example, the first fluid may be a high-pressure fluid and the second fluid may be a low-pressure fluid. The heat exchangersbeing integrated into the first circuitand the second circuitpermits a transfer of thermal energy between the first fluid and the second fluid. In preferred embodiments, the heat exchangersthat perform as a condenser permit the first fluid to be at least partially condensed by the second fluid and the heat exchangersthat perform as an evaporator permit the first fluid to be at least partially vaporized by the second fluid.

The thermal management systemmay further comprise more or less components and devices as necessary for operation. In some instances, the thermal management systemmay further include a compressor(e.g., a single-stage compressor, a vapor-injection compressor), an expansion valve, a controller (not depicted), and/or one or more sensors (not depicted). The thermal management systemmay be employed in a vehicle, for example, a vehicle having an electric motor, in particular a hybrid vehicle or a pure electric vehicle. It is understood, however, that the heat exchangermay be used in various other applications including, but not limited to, commercial, industrial, automotive, and residential heating, ventilation, and air conditioning (HVAC) applications.

illustrates the heat exchangeraccording to the present disclosure. In the embodiment depicted, a plurality of first plates(i.e., A-plates) and a plurality of second plates(i.e., A-plates rotated 180 degrees) are alternatingly arranged adjacent to one another side-by-side in a horizontally stacked relationship forming at least one A-Rotated A plate assemblybetween the opposing end plates,. In other embodiments, when the second platesare of a different design than the first plates(i.e., B-plates), the heat exchangermay comprise a plurality of first platesand a plurality of second platesalternatingly arranged adjacent to one another side-by-side in a horizontally stacked relationship forming at least one A-B plate assembly between opposing end plates,. It is understood that one or more of the end plates,may be part of a housing of the heat exchangerif desired. It is understood, however, that the heat exchangermay include any number of the plates,as desired.

Inlet ports,, and corresponding outlet ports,, for each of the first and second circuits,, respectively, are formed in one of the end plates,. In some embodiments, the inlet ports,, and the outlet ports,, are integrally formed with the one of the end plates,, yet in other embodiments they are formed as separate and distinct components that are coupled to the one of the end plates,. Each of the first and second plates,and/or each of the end plates,may be substantially elongate and rectangular. However, it is understood that the first and second plates,and the end plates,may have various shapes, sizes, and configurations as desired. In certain embodiments, the plates,may be configured to define one or more first flow paths for the first fluid and one or more second flow paths for the second fluid. In the embodiment shown in, the heat exchangeris a counter-flow heat exchanger having the first flow paths formed substantially parallel to the second flow paths, wherein a direction of flow of the first fluid through the heat exchangeris opposite a direction of flow of the second fluid through the heat exchanger. It is understood that the plates,and respective inlet ports,and outlet ports,may be so that the direction of flow of the first fluid through the heat exchangeris the same as the direction of flow of the second fluid through the heat exchanger.

In preferred embodiments, the first plateincludes an inflow openingand an outflow openingformed therein and the second plateincludes an inflow openingand an outflow opening. The inflow openings,may be fluidly connected to the inlet ports,, respectively, and the outflow openings,may be fluidly connected to the outlet ports,, respectively. The inflow openings,and the outflow openings,may be located in opposite corners of the respective first and second plates,. Accordingly, the first and second fluids may flow from the inflow openings,, through a substantial portion or across an entirety of the heat exchangerto the outflow openings,, thereby a distance from the inflow openings,to the outflow openings,that the first and second fluids have to travel may be maximized.

In the embodiment shown, each of the first platesmay further include one or more shaped sectionsformed therein. Each of the shaped sectionsurrounds a periphery of flow openings,formed in the first plateand abuts a first surfaceof the second plateto militate against leakage of the first fluid into the second flow paths and the second fluid into the first flow path.

In the embodiment shown, each of the second platesmay further include one or more shaped sectionformed therein. Each of the shaped sectionsurrounds a periphery of flow openings,formed in the second plateand abuts a first surfaceof the adjacent first plateto militate against leakage of the second fluid into the first flow paths and the first fluid into the second flow path.

It is understood that each of the openings,,,,,,,may be located elsewhere in the respective first and second plates,to achieve a desired thermal energy exchange between the first fluid and the second fluid.

The first flow path and the second flow path are formed alternately between the plates,and the end plates,. The openings,of the plates,, respectively, are fluidly connected to form an inlet manifold for the first fluid, which is fluidly coupled to the inlet port, and the openings,of the plates,, respectively, are fluidly connected to form an outlet manifold for the first fluid, which is fluidly coupled to the outlet port. As such, the first fluid of the first circuitflows into the inlet port, through the inlet manifold and the associated first flow paths defined by the plates,where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet manifold, and from the outlet portback into the first circuit. Similarly, the openings,of the plates,, respectively, are fluidly connected to form an inlet manifold for the second fluid, which is fluidly coupled to the inlet port, and the openings,of the plates,, respectively, are fluidly connected to form an outlet manifold for the second fluid, which is fluidly coupled to the outlet port. As such, the second fluid of the second circuitflows into the inlet port, through the inlet manifold and the associated second flow paths defined by the plates,where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet manifold, and from the outlet portback into the second circuit.

At least one thermal energy transfer device(e.g., a finned plate) may be disposed in at least a portion of the first flow path of the first fluid. The thermal energy transfer devicemay be configured to improve fluid flow distribution with the heat exchangerand overall performance thereof, as well as improve a rate of thermal energy transfer between the first fluid and the second fluid within the heat exchanger. As best shown in, the heat exchangerincludes one or more thermal energy transfer devicesdisposed between the first and second plates,. In some embodiments, at least one of the thermal energy transfer devicesis disposed in the first flow path for the first fluid between the first and second plates,. In other embodiments, one or more of the thermal energy transfer devices(shown in) is disposed in the first flow path for the first fluid between the first and second plates,and/or one or more thermal energy transfer devices(shown in) is disposed in the second flow path for the second fluid between the first and second plates,. It is understood that the thermal energy transfer devicemay be the thermal energy transfer devicerotated 180 degrees or vertically reflected with respect to a horizontal axis.

The thermal energy transfer devicemay include an inflow openingand an outflow openingformed therein to permit the flow of the first fluid therethrough and one or more openingsformed therein to accommodate the shaped sections. Similarly, the thermal energy transfer devicemay include an inflow openingand an outflow openingformed therein to permit the flow of the second fluid therethrough and one or more openingsformed therein to accommodate the shaped sections. It is understood, however, that the heat exchangermay include any number, or none, of the thermal energy transfer devices,as desired.

illustrate an exemplary embodiment of the thermal energy transfer devicehaving a flow diverterfor the first fluid according to the present disclosure. As best seen in, the thermal energy transfer devicecomprises a sheet. It is understood that the sheetmay be formed from any suitable method (e.g., a stamping process) and produced from any suitable material (e.g., a metal material). In some embodiments, the sheethas a generally serpentine and/or crenelated cross-sectional shape. It is understood, however, that the sheetmay have any suitable cross-sectional shape, size, and configuration as desired.

As shown, the sheethas a plurality of protuberances(e.g., fins, ribs, etc.), which define a plurality of flow channels. In some embodiments, one or more of the flow channelsmay be formed at an angle to the direction of flow of the first fluid through the heat exchanger. In a non-limiting example, one or more of the flow channelsmay be formed substantially perpendicular to the direction of flow of the first fluid through the heat exchangerand/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device. Thus, the flow channelsshown may be generally vertical flow channels. It is understood, however, that the flow channelsmay be generally horizontal flow channels depending on an orientation of the heat exchanger. One of more of the flow channelsmay extend across an entirety of the sheetfrom one longitudinal edge to an opposite longitudinal edge thereof. As best seen in, one or more of the flow channelsmay be fluidly connected to one or more adjacent flow channelsby one or more fluid passageways(i.e., windows) formed in the sheet. In other embodiments, the flow channelsmay be generally horizontal flow channels, extending across an entirety of the sheetfrom one lateral edge to an opposite lateral edge.

As depicted in, the flow divertermay be configured to prevent the flow of the first fluid through a certain portion of the fluid passageways, which causes the flow of the first fluid to be diverted. In some embodiments, the flow divertermay be formed at an angle to the direction of flow of the first fluid through the heat exchanger. In a non-limiting example, the flow divertermay be formed substantially perpendicular to the direction of flow of the first fluid through the heat exchangerand/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device. As depicted, the flow diverterhas a generally linear shape and configuration extending from a lower portion and/or a longitudinal edge portion of the sheetto a center portion and/or an opposite longitudinal edge portion thereof. In other embodiments, the flow divertermay extend from a lateral edge portion of the sheetto a center portion and/or an opposite lateral edge portion thereof. In some instances, the flow divertermay extend vertically or horizontally across at least half of the sheet. In other instances, the flow diverter may extend vertically or horizontally across less than half of the sheet. It is understood, however, the flow divertermay have any suitable shape, size, and configuration as desired to achieve improved flow distribution of the first fluid within the heat exchanger.