FLOW CONTROL DEVICE FOR A PLATE HEAT EXCHANGER

Description

FIELD

The disclosure relates to a heat exchanger, and more particularly to a flow control device for a plate heat exchanger.

BACKGROUND

Conventional air-conditioning and thermal management systems include a heat exchanger, for example, a plate heat exchanger. Plate heat exchangers consist of stacked plates in which two fluids, for example, a refrigerant and/or 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 here 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.

Beads, dimples, fins, or various other structures are usually formed and arranged in the flow channels to promote flow uniformity and improved heat transfer through increased surface area. Conventional plate heat exchangers, however, are vulnerable to single and multiple-phase flow maldistribution at any given flow rates. This phenomenon degrades an effective heat transfer across the plate heat exchanger, which negatively impacts an overall thermal system performance. Typically, the maldistribution of the refrigerant and/or coolant within the plate heat exchanger occurs under low flow rate conditions due to non-uniform and non-homogeneous distribution of the total flow divided across each of the flow channels. A pressure drop resulting from the maldistribution, particularly on the refrigerant side of the plate heat exchanger, limits an operating range of the compressor and affects an overall system efficiency.

Accordingly, it is desirable to develop a flow control device that improves flow distribution within a heat exchanger of a thermal management system to mitigate against maldistribution of fluids therein, which optimizes a performance of the heat exchanger, and thereby the thermal management system.

SUMMARY

In concordance and agreement with the presently described subject matter, a flow control device that improves flow distribution within a heat exchanger of a thermal management system to mitigate against maldistribution of fluids therein, which optimizes a performance of the heat exchanger, and thereby the thermal management system, has surprisingly been designed.

In one embodiment, a flow control device for a heat exchanger, comprises: a housing configured to be disposed in an inlet manifold of a heat exchanger; and a movable member disposed in the housing and configured to control a flow of a fluid through the heat exchanger, wherein the movable member is variably positionable to regulate the flow of the fluid through the heat exchanger based on an inflow momentum of the fluid entering into the heat exchanger.

In another embodiment, a heat exchanger, comprises: a plurality of plates in stacked relationship forming a plurality of flow channels, an inlet manifold, and an outlet manifold; and a flow control device disposed in the inlet manifold, the flow control device including: a housing; and a movable member disposed in the housing and configured to control a flow of a fluid through the heat exchanger, wherein the movable member is variably positionable to regulate the flow of the fluid through the flow channels of the heat exchanger based on an inflow momentum of the fluid entering into the heat exchanger.

In yet another embodiment, a method for controlling a thermal management system, comprises: providing a thermal management system including a heat exchanger fluidly connected to a first circuit for a first fluid and a second circuit for a second fluid, wherein at least one flow control device is disposed in an inlet manifold of the heat exchanger in the first circuit and/or the second circuit; and variably positioning a movable member of the at least one flow control device to regulate a flow of the first fluid and/or the second fluid through the flow channels within the heat exchanger based on an inflow momentum of the first fluid and/or second fluid entering into the heat exchanger.

As aspects of some embodiments, the heat exchanger is a plate heat exchanger.

As aspects of some embodiments, the heat exchanger is a chiller.

As aspects of some embodiments, the housing includes one or more openings formed therein to permit the flow of the fluid therethrough.

As aspects of some embodiments, the movable member is a plunger.

As aspects of some embodiments, the movable member is variably positionable to control a number of active flow channels of the heat exchanger.

As aspects of some embodiments, the at least one flow control device is configured to provide a liquid free, gaseous phase fluid to a compressor.

As aspects of some embodiments, the movable member is in a first position when the inflow momentum is relatively low and a second position when the inflow momentum is relatively high.

As aspects of some embodiments, the movable member is in an intermediate third position between the first position and the second position when the inflow momentum is relatively moderate between the relatively low inflow momentum and the relatively high inflow momentum.

As aspects of some embodiments, the movable member in a first position militates against the flow of the fluid through a portion of the heat exchanger.

As aspects of some embodiments, the movable member in a second position permits the flow of the fluid through an entirety of the heat exchanger.

As aspects of some embodiments, the movable member in an intermediate third position permits the flow of the fluid through a first portion of the heat exchanger and militates against the flow of the fluid through a remaining second portion of the heat exchanger.

As aspects of some embodiments, one or more engagement portions of the movable member sealingly engage the housing in a first position of the movable member to militate against the flow of the fluid through a number of flow channels of the heat exchanger.

As aspects of some embodiments, one or more engagement portions of the movable member are spaced from the housing in a second position of the movable member to permit the flow of the fluid around the movable member and through an entirety of the heat exchanger.

As aspects of some embodiments, one or more engagement portions of the movable member sealingly engage the housing in an intermediate third position to permit the flow of the fluid through a desired number of flow channels of the heat exchanger and militate against the flow of the fluid through a remaining number of flow channels of the heat exchanger.

As aspects of some embodiments, further comprising a biasing element configured to provide a biasing force against a force of the flow of the fluid.

As aspects of some embodiments, the movable member is in a first position when the force of the flow of the fluid into the heat exchanger is less than the biasing force of the biasing element of the flow control device.

As aspects of some embodiments, the movable member is in a second position when the force of the flow of the fluid into the heat exchanger is greater than the biasing force of the biasing element of the flow control device.

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.

BRIEF DESCRIPTION

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a bottom perspective view of a heat exchanger in accordance with an embodiment of the present disclosure, including an exploded view of an embodiment of a flow control device disposed in an inlet manifold of the heat exchanger;

FIG. 2 is a top plan view of the heat exchanger of FIG. 1;

FIG. 3 is a schematic diagram of a thermal management system including the heat exchanger of FIGS. 1 and 2 in accordance with an embodiment of the present disclosure;

FIG. 4 is an elevational view of the flow control device of FIG. 1;

FIG. 5 is a cross-sectional view of the flow control device shown in FIGS. 1 and 4;

FIG. 6 is a cross-sectional view of the heat exchanger of FIGS. 1 and 2 taken along section line A-A of FIG. 2, showing a movable member of the flow control device in a first position;

FIG. 7A is a cross-sectional view of the heat exchanger of FIGS. 1 and 2 taken along section line A-A of FIG. 2, showing a movable member of the flow control device in a first position permitting a flow of a fluid into a number of flow channels and militating against the flow of the fluid into a remaining number of flow channels, wherein an inflow momentum of the fluid into the heat exchanger is relatively low;

FIG. 7B is a cross-sectional view of the heat exchanger of FIGS. 1 and 2 taken along section line A-A of FIG. 2, showing a movable member of the flow control device in a second position permitting the flow of the fluid into all of flow channels and an entirety of the heat exchanger, wherein the inflow momentum of the fluid into the heat exchanger is relatively high;

FIG. 7C is a cross-sectional view of the heat exchanger of FIGS. 1 and 2 taken along section line A-A of FIG. 2, showing a movable member of the flow control device in an intermediate position between a first position and a second position permitting a flow of a fluid into a number of flow channels and militating against the flow of the fluid into a remaining number of flow channels, wherein the flow of the fluid is permitted through more flow channels than when the movable member is in the first position and less flow channels than when the movable member is in the second position, and wherein the inflow momentum of the fluid into the heat exchanger is relatively moderate between the relatively high inflow momentum and the relatively low inflow momentum;

FIG. 8 depicts a maldistribution of a two-phase first fluid within a conventional heat exchanger, wherein a substantial portion of the heat exchanger, particularly flow channels opposite an inlet port for the first fluid are not participating in thermal energy transfer between the first fluid and a second fluid; and

FIG. 9 depicts an improved distribution of a two-phase first fluid within a heat exchanger including a flow control device in accordance with an embodiment of the present disclosure, wherein the flow control device is in a first position permitting a flow of the fluid through only a desired number of flow channels and militating against the flow of the fluid through a remaining number of flow channels, which increases turbulence and flow uniformity in the flow channels that are actively participating in thermal energy transfer between the first fluid and a second fluid.

DETAILED DESCRIPTION

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.

FIGS. 1 and 2 illustrate a heat exchanger 10 including a flow control device 12 according to an embodiment of the present disclosure. In some embodiments, multiple heat exchangers 10 may be employed in a thermal management system 2 as shown in FIG. 3. The thermal management system 2 may further comprise more or less components and devices as necessary for operation. In some instances, the thermal management system 2 may further include a compressor 20 (e.g., a single-stage compressor, a vapor-injection compressor), an expansion valve 22, a controller (not depicted), and/or one or more sensors (not depicted). The thermal management system 2 may 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 exchanger 10 may be used in various other applications including, but not limited to, commercial, industrial, automotive, and residential heating, ventilation, and air conditioning (HVAC) applications.

In some embodiments, the heat exchanger 10 may perform as an evaporator (e.g., a chiller) and/or a condenser (e.g., a water-cooled condenser (WCC)). The heat exchanger 10 is depicted as a plate heat exchanger, however, it is understood that the heat exchanger 10 may be other various types of heat exchangers if desired. The heat exchanger 10 may be fluidly connected and/or in fluid communication with a first circuit 14 for a first fluid (e.g., a refrigerant, coolant, etc.) and a second circuit 16 for a second fluid (e.g. a refrigerant, a coolant, etc.). 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 exchanger 10 being integrated into the first circuit 14 and the second circuit 16 permits the first fluid to transfer thermal energy between the first fluid and the second fluid. In preferred embodiments, the heat exchanger 10 permits the first fluid (e.g., the refrigerant) to be vaporized by the second fluid (e.g., the coolant).

In some embodiments, the heat exchanger 10 comprises a plurality of first plates 30 and a plurality of second plates 31 alternatingly arranged in a stacked relationship between opposing end plates 32, 34. It is understood that one or more of the end plates 32, 34 may be part of a housing of the heat exchanger 10 if desired. It is understood that the heat exchanger 10 may include any number of the plates 30, 31 as desired.

Inlet ports 36, 38 and corresponding outlet ports 40, 42 may formed in one of the end plates 32, 34. In some embodiments, the inlet port 36 and the outlet port 40 may be fluidly connected to the first circuit 14 for a flow of the first fluid through the heat exchanger 10, and the inlet port 38 and the outlet port 42 may be fluidly connected to the second circuit 16 for a flow of the second fluid through the heat exchanger 10. One or more of the inlet ports 36, 38 and the outlet ports 40, 42 may be integrally formed with the one of the end plates 32, 34. Yet, in other embodiments, one or more of the inlet ports 36, 38 and the outlet ports 40, 42 may be formed as separate and distinct components that are coupled to the one of the end plates 32, 34. Each of the first and second plates 30, 31 and/or each of the end plates 32, 34 may be substantially elongate and rectangular. However, it is understood that the first and second plates 30, 31 and the end plates 32, 34 may have various shapes, sizes, and configurations as desired.

As best shown in FIGS. 6-7C, each of the first and second plates 30, 31 includes an inflow opening 43 and an outflow opening (not depicted) for the first fluid formed therein. The inflow openings 43 of the plates 30, 31 may be in fluid communication with each other to form an inlet manifold 44 for the first fluid, which may be fluidly connected to the inlet port 36. Likewise, the outflow openings may be in fluid communication with each other to form an outlet manifold (not depicted) for the first fluid, which is fluidly connected to the outlet port 40. In some embodiments, the inflow openings 43 and the outflow openings may be diagonally opposed being located in diagonally opposite corners of the respective first and second plates 30, 31.

Thus, a distance from the inflow openings 43 to the outflow openings that the first fluid has to travel may be maximized.

Each of the first and second plates 30, 31 further includes an inflow opening 45 and an outflow opening (not depicted) for the second fluid formed therein. The inflow openings 45 of the plates 30, 31 may be in fluid communication with each other to form an inlet manifold 46 for the second fluid, which may be fluidly connected to the inlet port 38. Likewise, the outflow openings may be in fluid communication with each other to form an outlet manifold (not depicted) for the second fluid, which is fluidly connected to the outlet port 42. In certain embodiments, the inflow openings 45 and the outflow openings may be diagonally opposed being located in diagonally opposite corners of the respective first and second plates 30, 31. Thus, a distance from the inflow openings 45 to the outflow openings that the second fluid has to travel may be maximized.

It is understood that each of the inflow openings 43, 45, the outflow openings, the inlet manifolds 44, 46, and the outlet manifolds may be located elsewhere in the respective first and second plates 30, 31 to achieve a desired thermal energy exchange between the first fluid and the second fluid.

As best seen in FIG. 6, the plates 30, 31 may be configured to define one or more flow channels 48 for the first fluid and one or more flow channels 50 for the second fluid. The flow channels 48 and the flow channels 50 may be formed alternately between the plates 30, 31. It is understood, however, that other arrangements of the flow channels 48, 50 within the heat exchanger 10 may be employed. At least one thermal energy transfer device, for example, fins, may be disposed in at least a portion of at least one of the flow channels 48, 50 to enhance and improve a rate of thermal energy transfer between the first fluid and the second fluid within the heat exchanger 10.

Accordingly, the first fluid from the first circuit 14 may flow into the inlet port 36, through the inflow openings 43 and the inlet manifold 44, through a portion or an entirety of the heat exchanger 10, via the flow channels 48, where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet openings and the outlet manifold, and from the outlet port 40 back into the first circuit 14. Similarly, the second fluid from the second circuit 16 may flow into the inlet port 38, through the inflow openings 45 and the inlet manifold 46, through a portion or an entirety of the heat exchanger 10, via the flow channels 50, where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet openings and the outlet manifold, and from the outlet port 42 back into the second circuit 16.

In some embodiments, the flow control device 12 may be disposed in the inlet manifold 44 of the heat exchanger 10 in the first circuit 14 (as shown in FIGS. 6-7C). In other embodiments, the flow control device 12 may be disposed in the inlet manifold 44 and/or the inlet manifold 46 of the heat exchanger 10 in the respective first circuit 14 and/or the second circuit 16.

The flow control device 12 may be configured to regulate the flow of the first fluid and/or the second fluid within the heat exchanger 10 based upon an inflow momentum of the respective first fluid and/or the second fluid entering into the heat exchanger 10. In some embodiments, the flow control device 12 regulates the flow of the first fluid through the flow channels 48 and/or the flow of the second fluid through the flow channels 50, thereby improving flow distribution and mitigating maldistribution within the heat exchanger 10. In a non-limiting example, the flow control device 12 may be configured to permit the flow of the first fluid and/or the second fluid through a desired number of the respective flow channels 48, 50 (referred to herein as “active flow channels”) and militate against the flow of the first fluid and/or the second fluid through a remaining number of the respective flow channels 48, 50 (referred to herein as “inactive flow channels”) based on the inflow momentum of the first fluid and/or the second fluid entering the heat exchanger 10. In another non-limiting example, the flow control device 12 may be configured to permit the flow of the first fluid and/or the second fluid through all of the respective flow channels 48, 50 and an entirety of the heat exchanger 10 based on the inflow momentum of the first fluid and/or the second fluid entering into the heat exchanger 10. Thus, the flow control device 12 may be configured so that an optimal number of the flow channels 48 for the first fluid and/or the flow channels 50 for the second fluid are actively participating in thermal energy transfer between the first fluid and the second fluid. As a result, the first fluid, in only a gaseous phase (i.e., vapor), flows from the heat exchanger 10 to the compressor 20 in the first circuit 14, which thereby improves a performance of the thermal management system 2.

In certain embodiments, the flow control device 12 does not regulate the flow of the first fluid through a specific number of the flow channels 48 and/or the flow of the second fluid through a specific number of the flow channels 50 so that those flow channels 48, 50 are continuously active flow channels to prevent damage to the heat exchanger 10 in the event of malfunction in the thermal management system 2. For example, the heat exchanger 10 depicted in FIGS. 7A-7C includes three continuously active flow channels 48. It is understood that the number of continuously active flow channels 48, 50 may be any suitable number as desired to optimize the performance of the heat exchanger 10 and/or the thermal management system 2.

In some embodiments, the flow control device 12 may be inserted into one or more of the inlet manifolds 44, 46 via an opening 58 of a ring member 60 placed during an assembly of the plates 30, 31, 32, 34. In certain instances, the ring member 60 may be fixedly coupled to the heat exchanger 10 during the same brazing process used to assemble the plates 30, 31, 32, 34. A plug member 62 may be disposed in the opening 58 of the ring member 60 after installation of the flow control device 12 to maintain a position of the flow control device 12 and militate against leakage of the first fluid and/or the second fluid from the heat exchanger 10. In some embodiments, the plug member 62 may be in sealing engagement (e.g., via a threaded connection, a sealing element, etc.) with the ring member 60 to form a substantially fluid-tight seal therebetween.

As best seen in FIG. 1, the flow control device 12 may comprise a housing 64, a movable member 66 situated coaxially within the housing 64, and a biasing element 68 to provide a biasing force (i.e., primary resisting force) against a force of the flow of the fluid (i.e., primary driving force). Although the biasing element 68 depicted is a helical spring, it is understood that various other types of biasing elements may be employed.

In some embodiments depicted in FIGS. 4 and 5, the housing 64 may be a generally cylindrical tube-like structure having a center bore 70 extending from a first end 72 to a second end 74 along a longitudinal axis thereof. The center bore 70 has a size, shape, and configuration suitable to receive the movable member 66 therein. As more clearly shown in FIG. 4, one or more apertures 76 may be formed through a circumferential wall 78 of the housing 64 to permit the flow of the first fluid and/or the second fluid around and through the housing 64. Although the apertures 76 shown are generally oval shaped, it is understood that the apertures 76 may have any suitable size, shape, and configuration as desired.

An outwardly extending annular flange 80 may be formed at the second end 74 of the housing 64 to engage one of the plates 30, 31, 32, 34 and/or the ring member 60 to prevent the flow control device 12 from being inserted too far into the inlet manifolds 44, 46 during installation thereof. An outer surface of the housing 64 may include one or more radially outwardly extending portions 82 configured to sealingly engage an inner surface of the openings 43 of the plates 30, 31 to form a substantially fluid-tight seal therebetween. As more clearly shown in FIG. 5, an inner surface of the housing 64 may include engagement portions 84a, 84b. Each of the engagement portions 84a, 84b is in axial alignment with a corresponding one of the radially outwardly extending portions 82 and configured to sealingly engage a respective one of the engagement portions 85a, 85b of the movable member 66. A sealing element (not depicted) may be provided on each of the engagement portions 84a, 84b of the housing 64 to form a substantially fluid-tight seal when engaged with the engagement portion 85a, 85b of the movable member 66. The portions 82, 84a, 84b are formed at specific locations on the housing 64 to permit and militate against the flow of the first fluid and/or the second fluid through a desired number of the respective flow channels 48, 50.

Referring back to FIG. 1, the movable member 66 may be any suitable plunger or plunger-like device. Various other types of moveable devices may be employed, if desired. In certain embodiments, the movable member 66 includes a first end 86 and an opposing second end 88.

The engagement portion 85a of the movable member 66 may be formed at the first end 86 and the engagement portion 85b may be formed on the movable member 66 intermediate the first and second ends 86, 88. A sealing element (not depicted) may be provided on each of the engagement portions 85a, 85b of the movable member 66 to form a substantially fluid-tight seal when engaged with the engagement portion 84a, 84b of the housing 64. As depicted in FIGS. 6-7C, the second end 88 of the movable member 66 may be configured to perform as a guide for the biasing element 68.

In a preferred embodiment, the flow control device 12 is disposed in the inlet manifold 44 of the heat exchanger 10 and the movable member 66 may be configured to be variably positionable between a first position (as shown in FIG. 7A), a second position (as shown in FIG. 7B), and intermediate third positions (as shown in FIG. 7C) between the first and second positions based on the inflow momentum of the first fluid entering the heat exchanger 10. The movable member 66 may be in the first position when the inflow momentum of the first fluid is relatively low and the force of the flow of the first fluid into the heat exchanger 10 is less than the biasing force of the biasing element 68 of the flow control device 12. The movable member 66 may be in the second position when the inflow momentum of the first fluid is relatively high and the force of the flow of the first fluid into the heat exchanger 10 is greater than the biasing force of the biasing element 68 of the flow control device 12. Additionally, the movable member 66 may be in the intermediate third positions between the first position and the second position when the inflow momentum of the first fluid is relatively moderate (i.e., between the relatively low inflow momentum and the relatively high inflow momentum) and the force of the flow of the first fluid into the heat exchanger 10 urges the biasing element 68 (i.e., compresses) until the biasing force of the biasing element 68 is generally equivalent thereto.

FIG. 7A illustrates an exemplary embodiment of the heat exchanger 10 having the movable member 66 in the first position. The heat exchanger 10 includes a number of continuously active flow channels 48 provided a first portion thereof (as depicted by arrows in FIG. 7A) and the movable member 66, in the first position, militates against the flow of the first fluid through a remaining second portion of the heat exchanger 10. The first portion is smaller than the second portion of the heat exchanger 10. In certain embodiments, the engagement portion 85a of the movable member 66 sealingly engages the engagement portion 84a of the housing 64 to militate against the flow of the first fluid through a remaining number of flow channels 48 of the heat exchanger 10. As a result, the number of active flow channels 48 is less than the number of inactive flow channels 48 of the heat exchanger 10.

FIG. 7B illustrates an exemplary embodiment of the heat exchanger 10 having the movable member 66 in the second position. As shown, the heat exchanger 10 includes a number of continuously active flow channels 48 and the movable member 66, in the second position, permits the flow of the first fluid through an entirety of a remaining number of the flow channels 48 of the heat exchanger 10 (as depicted by arrows in FIG. 7B). Particularly, both of the engagement portions 85a, 85b of the movable member 66 are spaced from the engagement portions 84a, 84b of the housing 64 to permit the flow of the first fluid through the apertures 76 formed in the housing 65, around the movable member 66, and through all of the flow channels 48 and an entirety of the heat exchanger 10. As a result, the number of active flow channels 48 is maximized.

FIG. 7C illustrates an exemplary embodiment of the heat exchanger 10 having the movable member 66 in one of the intermediate third positions. The heat exchanger 10 includes a number of continuously active flow channels 48 and the movable member 66, in the third position, permits the flow of the first fluid through a first portion of the heat exchanger 10 and militates against the flow of the first fluid through a remaining second portion of the heat exchanger 10 (as depicted by arrows in FIG. 7C). As shown, the first portion is greater than the second portion of the heat exchanger 10. Specifically, the engagement portion 85b of the movable member 66 sealingly engages the engagement portion 84b of the housing 64 to permit the flow of the first fluid through a desired number of flow channels 48 of the heat exchanger 10 and militate against the flow of the first fluid through a remaining number of flow channels 48 of the heat exchanger 10. As a result, the number of active flow channels 48 is greater than the number of inactive flow channels 48 of the heat exchanger 10, and greater than the number of active flow channels 48 when the movable member 66 is in the first position.

It should be appreciated that in other embodiments described hereinabove, the flow control device 12 may also be disposed in the inlet manifold 45 for the second fluid to regulate the flow of the second fluid through the heat exchanger 10 based on the inflow momentum of the second fluid entering the heat exchanger 10. A structure and operation of the flow control device 12 disposed in the inlet manifold 46 for the second fluid is substantially similar or the same as that of the flow control device 12 disposed in the inlet manifold 44 for the first fluid, and for simplicity purposes, the description of such is not repeated herein.

Maldistribution of the first fluid occurs within conventional heat exchangers, especially during low mass flow rates of the first fluid. FIG. 8 depicts such maldistribution of a two-phase fluid (via liquid volume fraction) within the conventional heat exchangers under conventional methods of operation. As depicted, the fluid does not flow through a substantial number of the flow channels and therefore, are not participating in thermal energy transfer between the first and second fluids (i.e., thermally inactive).

An improved distribution of the first fluid occurs within the heat exchanger 10 under a method of operation of the thermal management system 2 in accordance with an embodiment present disclosure. FIG. 9 illustrates an improved distribution of a two-phase first fluid within the heat exchanger 10. As illustrated, the first fluid flows through a desired number of the flow channels 44 of three plates 30, 31 after a time period t (i.e., t >0), and therefore, only active flow channels are actively participating in thermal energy transfer between the first fluid and a second fluid.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.