MULTI-FLUID HEAT EXCHANGER

Description

INTRODUCTION

The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

The present disclosure relates to a heat exchanger including more than two channels and configured to transfer heat between more than two fluids.

Heat exchangers transfer heat between two or more fluids without mixing the fluids. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact. Heat exchangers are used in, for example, automotive applications, space heating, refrigeration, air conditioning, power stations, chemical plants, petrochemical plants, petroleum refineries, natural-gas processing, and sewage treatment. An example of a heat exchanger is found in an internal combustion engine in which engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. Another example is a heat sink, which is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant. Heat exchangers are also used in electric vehicles for thermal management.

SUMMARY

The present disclosure provides for, in various features, a heat exchanger including: a housing defining a chamber therein; a coolant inlet, a coolant outlet, and coolant channels defined within the chamber extending between the coolant inlet and the coolant outlet; a first fluid inlet, a first fluid outlet, and first fluid channels defined within the chamber extending between the first fluid inlet and the first fluid outlet; and a second fluid inlet, a second fluid outlet, and second fluid channels defined within the chamber extending between the second fluid inlet and the second fluid outlet. The coolant channels, the first fluid channels, and the second fluid channels are all intertwined and thereby configured to simultaneously transfer heat between coolant flowing through the coolant channels and each of a first fluid flowing through the first fluid channels and a second fluid flowing through the second fluid channels.

In further features: the coolant inlet is aligned linearly with the coolant outlet; the first fluid inlet is aligned linearly with the first fluid outlet; and the second fluid inlet is aligned linearly with the second fluid outlet.

In further features, the coolant inlet and the coolant outlet extend perpendicular to the first fluid inlet and the first fluid outlet, and extend perpendicular to the second fluid inlet and the second fluid outlet; and the first fluid inlet and the first fluid outlet extend perpendicular to the second fluid inlet and the second fluid outlet.

In further features: the housing is a cylinder including a first end and a second end opposite to the first end, both the coolant inlet and the coolant outlet are at the first end; and the coolant channels include a main coolant channel extending along an axial center of the of the cylinder, and outer coolant channels surrounding the main coolant channel, the outer coolant channels are intertwined with both the first fluid channels and the second fluid channels.

In further features, the coolant channels surround each of the first fluid channels and the second fluid channels.

In further features, reinforcement members are within the coolant channels, the reinforcement members contacting exterior surfaces of at least one of the first fluid channels and the second fluid channels to support at least one of the first fluid channels and the second fluid channels.

In further features, the first fluid inlet and the first fluid outlet are offset along a length of the housing; and the second fluid inlet and the second fluid outlet are offset along the length of the housing.

In further features, the heat exchanger includes a first baffle within the chamber extending through the first fluid channels, and configured to direct the first fluid from the first fluid inlet to the first fluid outlet along a first path extending along a length of the chamber past the second fluid inlet and the second fluid outlet.

In further features, the heat exchanger includes a second baffle within the chamber extending through the second fluid channels, and configured to direct the second fluid from the second fluid inlet to the second fluid outlet along a second path extending along the length of the chamber past the first fluid inlet and the first fluid outlet.

In further features, the first baffle seals against an inner surface of the housing between the first fluid inlet and the first fluid outlet; and the second baffle seals against the inner surface of the housing between the second fluid inlet and the second fluid outlet.

In further features, at the first fluid inlet and the first fluid outlet are first openings of the first fluid channels, the second fluid channels are closed at the first fluid inlet and the first fluid outlet; and at the second fluid inlet and the second fluid outlet are second openings of the second fluid channels, the first fluid channels are closed at the second fluid inlet and the second fluid outlet.

In further features, the heat exchanger includes a first coolant buffer of the coolant channels between the first fluid inlet and the second fluid channels, and between the first fluid outlet and the second fluid channels; and a second coolant buffer of the coolant channels between the second fluid inlet and the first fluid channels, and between the second fluid outlet and the first fluid channels.

In further features, the housing defines a first inlet plenum at the first fluid inlet around inlet openings of the first fluid channels; the housing defines a first outlet plenum at the first fluid outlet around outlet openings of the first fluid channels; the housing defines a second inlet plenum at the second fluid inlet around inlet openings of the second fluid channels; and the housing defines a second outlet plenum at the second fluid outlet around outlet openings of the second fluid channels.

In further features, the coolant channels, the first fluid channels, and the second fluid channels are defined by a lattice structure.

In further features, the housing is sealed to the lattice structure between the first fluid inlet and the first fluid outlet; the housing is sealed to the lattice structure between the first fluid outlet and the second fluid inlet; and the housing is sealed to the lattice structure between the second fluid inlet and the second fluid outlet.

The present disclosure further includes, in various features, a heat exchanger including: a housing defining a chamber therein; a coolant inlet aligned linearly with a coolant outlet, and coolant channels defined within the chamber extending between the coolant inlet and the coolant outlet; a first fluid inlet aligned linearly with a first fluid outlet, and first fluid channels defined within the chamber extending between the first fluid inlet and the first fluid outlet; and a second fluid inlet aligned linearly with a second fluid outlet, and second fluid channels defined within the chamber extending between the second fluid inlet and the second fluid outlet. The coolant channels surround each one of the first fluid channels and the second fluid channels. The coolant channels, the first fluid channels, and the second fluid channels are all intertwined and thereby configured to simultaneously transfer heat between coolant flowing through the coolant channels and each of a first fluid flowing through the first fluid channels and a second fluid flowing through the second fluid channels.

In further features, the coolant inlet and the coolant outlet extend perpendicular to the first fluid inlet and the first fluid outlet, and extend perpendicular to the second fluid inlet and the second fluid outlet; and the first fluid inlet and the first fluid outlet extend perpendicular to the second fluid inlet and the second fluid outlet.

In further features, the coolant channels, the first fluid channels, and the second fluid channels are defined by a three-dimensional lattice structure.

The present disclosure also provides for, in various features, a heat exchanger including: a coolant inlet, a coolant outlet, and coolant channels defining a non-linear path extending between the coolant inlet and the coolant outlet; a first fluid inlet, a first fluid outlet, and first fluid channels defining a non-linear path extending between the first fluid inlet and the first fluid outlet; and a second fluid inlet, a second fluid outlet, and second fluid channels defining a non-linear path extending between the second fluid inlet and the second fluid outlet. The coolant channels, the first fluid channels, and the second fluid channels are all intertwined and thereby configured to simultaneously transfer heat between coolant flowing through the coolant channels and each of a first fluid flowing through the first fluid channels and a second fluid flowing through the second fluid channels. The coolant channels, the first fluid channels, and the second fluid channels are defined by a three-dimensional lattice structure.

In further features, at the first fluid inlet and the first fluid outlet are first openings of the first fluid channels, the second fluid channels are closed at the first fluid inlet and the first fluid outlet. At the second fluid inlet and the second fluid outlet are second openings of the second fluid channels, the first fluid channels are closed at the second fluid inlet and the second fluid outlet.

Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a heat exchanger in accordance with the present disclosure;

FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

FIG. 3 illustrates the heat exchanger of FIG. 1 without an outer housing;

FIG. 4 is a cross-sectional view of an additional heat exchanger in accordance with the present disclosure;

FIG. 5 is another cross-sectional view of the heat exchanger of FIG. 4;

FIG. 6 illustrates a lattice structure of various fluid channels defined by a heat exchanger in accordance with the present disclosure;

FIG. 7 is a perspective view of an additional heat exchanger in accordance with the present disclosure; and

FIG. 8 is a cross-sectional view of the heat exchanger of FIG. 7.

In the drawings, reference numbers may be reused to identify similar and/or identical elements.

DETAILED DESCRIPTION

The present disclosure is directed to heat exchangers configured to exchange heat between three or more different fluids. The heat exchangers define three or more fluid channels to accommodate the different fluids. The fluid channels are intertwined and configured to simultaneously transfer heat between the different fluids. Because all of the channels are intertwined throughout a majority of the heat exchangers, the heat exchangers of the present disclosure are configured to enhance heat exchange between the different fluids and improve the overall efficiency of the heat exchangers.

The heat exchangers of the present disclosure are configured for use in any suitable automotive and non-automotive applications. With respect to automotive applications, for example, the heat exchangers may be configured to facilitate thermal management. For example and with respect to battery thermal management, the heat exchangers of the present disclosure are configured to help maintain a battery pack at optimal temperature. The heat exchangers can cool the battery when it gets too hot, and warm the battery in cold conditions to ensure efficient operation. With respect to cabin heating and cooling, the heat exchangers of the present disclosure may be configured for use with the heating, ventilation, and air conditioning (HVAC) system of any suitable fully electric vehicle (or partially electric vehicle) to manage cabin temperature. The heat exchangers of the present disclosure may be configured to cool vehicle motors and cool vehicle electronics. The heat exchangers may be configured for use with reversible heat pumps, which can act as both a heater and a cooler. The systems are able to transfer excess heat from the battery to the cabin or vice versa, thereby improving efficiency of the system. The heat exchangers of the present disclosure are configured for any other suitable automotive and non-automotive applications as well.

FIGS. 1-3 illustrate a heat exchanger 10 in accordance with the present disclosure. The heat exchanger 10 includes a housing 20, which defines a chamber 22 (FIG. 2) therein. The housing 20 may have any suitable shape and size, which will depend on the application. In the example illustrated, the housing 20 is generally shaped as a cylinder. An axis X extends through a radial center of the housing 20.

The housing 20 defines various inlets and outlets for fluid. In the example illustrated, a coolant inlet 30 and a coolant outlet 32 are at a first end of the cylinder. The coolant inlet 30 and the coolant outlet 32 may be at any other suitable position about the cylinder depending on the application. With reference to FIG. 2, extending within the chamber 22 from the coolant inlet 30 is a main coolant channel 34, which extends along the longitudinal axis X. The main coolant channel 34 extends from the coolant inlet 30 to an opposite end of the chamber 22. Surrounding the main coolant channel 34 are outer coolant channels 36, which are intertwined with channels for other fluids passing through the heat exchanger 10.

The housing 20 further defines a first fluid inlet 40 and a first fluid outlet 42, which are spaced apart along a length of the housing 20. The first fluid inlet 40 and the first fluid outlet 42 may be radially offset as illustrated in FIG. 1, or aligned. First fluid channels 44 are defined within the chamber 22 and extend between the first fluid inlet 40 and the first fluid outlet 42. The first fluid channels 44 do not extend linearly, but rather define multiple different paths from the first fluid inlet 40 to the first fluid outlet 42.

The housing 20 also defines a second fluid inlet 50 and a second fluid outlet 52, which are spaced apart along the length of the housing 20. The second fluid inlet 50 and the second fluid outlet 52 may be radially offset as illustrated in FIG. 1, or aligned. Second fluid channels 54 are defined within the chamber 22 and extend between the second fluid inlet 50 and the second fluid outlet 52. The second fluid channels 54 do not extend linearly, but rather define multiple different paths from the second fluid inlet 50 to the second fluid outlet 52.

The first fluid channels 44 and the second fluid channels 54 are all generally provided as a lattice structure, which may be formed in any suitable manner, such as by any suitable additive manufacturing process (e.g., 3D-printing). The heat exchanger illustrated in FIGS. 1-3 illustrates only two sets of fluid channels (the first fluid channels 44 and the second fluid channels 54). But the heat exchanger 10 may be configured to include any suitable number of additional fluid channels for accommodating heat exchange between any suitable number of additional fluids. The additional fluid channels will be intertwined within the chamber 22 with the first fluid channels 44, the second fluid channels 54, and the outer coolant channels 36. Any suitable number of additional fluid channels may be included, such as 5, 10, 50, 100, etc.

FIG. 3 illustrates the heat exchanger 10 with the housing 20 removed. The heat exchanger 10 includes various outer flanges that are sealed to the housing 20 to divide the heat exchanger 10 into different areas to facilitate fluid flow (see FIG. 2, for example). In the example illustrated, a first flange 60 and a second flange 62 are sealed to an inner surface of the housing 20 on opposite sides of the first fluid inlet 40 to define a first inlet plenum 82. Only the first fluid channels 44 have openings at the first inlet plenum 82. Thus, a first fluid entering the heat exchanger 10 through the first fluid inlet 40 flows into the first inlet plenum 82 and into the first fluid channels 44.

The second flange 62 and a third flange 64 are sealed to the inner surface of the housing 20 on opposite sides of the first fluid outlet 42 to define a first outlet plenum 84. Only the first fluid channels 44 have outlets at the first outlet plenum 84. Thus, the first fluid exits the first fluid channels 44 into the first outlet plenum 84 and exits the heat exchanger 10 through the first fluid outlet 42.

The third flange 64 and a fourth flange 66 are sealed to the inner surface of the housing 20 on opposite sides of a second fluid inlet 50 to define a second inlet plenum 86. Only the second fluid channels 54 have openings at the second inlet plenum 86. Thus, a second fluid entering the heat exchanger 10 through the second fluid inlet 50 flows into the second inlet plenum 86 and into the second fluid channels 54.

The fourth flange 66 and a fifth flange 68 are sealed to the inner surface of the housing 20 on opposite sides of the second fluid outlet 52 to define a second outlet plenum 88. Only the second fluid channels 54 have outlets at the second outlet plenum 88. Thus, the second fluid exits the second fluid channels 54 into the second outlet plenum 88 and exits the heat exchanger 10 through the second fluid outlet 52.

The heat exchanger 10 further includes a baffle 70 within the chamber 22, which extends along a length of the housing 20 generally parallel to the longitudinal axis X. The baffle 70 is divided into a first baffle portion that only extends through the first fluid channels 44, and a second baffle portion that only extends through the second fluid channels 54. A first baffle flange 72 is sealed to the second flange 62. A second baffle flange 74 is sealed to the fourth flange 66. The first baffle flange 72 is only within the first fluid channels 44, and not within the second fluid channels 54. The second baffle flange 74 is only within the second fluid channels 54, and not within the first fluid channels 44.

The first baffle portion of the baffle 70 and the first baffle flange 72, which extend through the first fluid channels 44, are configured to direct the first fluid from the first fluid inlet 40 to the first fluid outlet 42 along a first path extending along a length of the chamber 22 past the second fluid inlet 50 and the second fluid outlet 52. The second baffle portion of the baffle 70 and the second baffle flange 74, which extend through the second fluid channels 54, are configured to direct the second fluid from the second fluid inlet 50 to the second fluid outlet 52 along a second path extending along a length of the chamber 22 past the first fluid inlet 40 and the first fluid outlet 42.

The heat exchanger 10 may further include a coolant buffer 80 around an exterior portion of the lattice structure defining openings of the first fluid channels 44 and the second fluid channels 46. The coolant buffer 80 is in fluid communication with the outer coolant channels 36, and is an extension of the outer coolant channels 36. The coolant buffer 80 surrounds the openings of the first fluid channels 44 at the first inlet plenum 82 and the first outlet plenum 84. And the coolant buffer 80 surrounds the openings of the second fluid channels 54 at the second inlet plenum 86 and the second outlet plenum 88. The coolant buffer 80 facilitates cooling of the first and second fluid channels 44, 54 at the inlets and the outlets thereof.

FIGS. 4 and 5 are cross-sectional views of an additional heat exchanger 110 in accordance with the present disclosure. The heat exchanger 110 includes the coolant inlet 30, the coolant outlet 32, and the coolant channels 36 of the heat exchanger 10, The heat exchanger 110 also includes the first fluid inlet 40, the first fluid outlet 42, the first fluid channels 44, the second fluid inlet 50, the second fluid outlet 52, and the second fluid channels 54. In addition, the heat exchanger 110 includes a third fluid inlet 90, a third fluid outlet 92, and third fluid channels 94. The third fluid channels 94 are intertwined with the coolant channels 36, first fluid channels 44, and the second fluid channels 54 to simultaneously transfer heat between liquid flowing through the coolant channels 36, the first fluid channels 44, the second fluid channels 54, and the third fluid channels 94. Any suitable number of additional fluid channels may be included and intertwined with the coolant channels 36 and the other fluid channels to simultaneously transfer heat between the liquids of the different channels. As illustrated in FIG. 5, the heat exchanger 110 may include the coolant buffer 80 at one or more of the inlets and outlets of the heat exchanger 110. The coolant buffer 80 is in fluid communication with the coolant channels 36, and is an extension of the coolant channels 36. The coolant buffer 80 surrounds inlets and the outlets of the first fluid channels 44, surrounds the inlets and the outlets of the second fluid channels 54, and surrounds the inlets and the outlets of the third fluid channels 94. The coolant buffer 80 facilitates cooling of the different fluid channels at inlets and outlets thereof.

FIG. 6 illustrates an exemplary lattice structure 24 of the present disclosure defining the outer coolant channels 36, the first fluid channels 44, and the second fluid channels 54. Structural reinforcement members 56 are includes to provide support to the first fluid channels 44 and/or the second fluid channels 54. In the example illustrated, the structural reinforcement members 56 extend through the outer coolant channels 36.

FIGS. 7 and 8 illustrate an additional heat exchanger 210 in accordance with the present disclosure. Unlike the cylinder shape of the heat exchanger 10, the heat exchanger 210 is configured to have a cube-like or round shape. The heat exchanger 210 includes the coolant inlet 30, the coolant outlet 32, and the coolant channels 36 extending therebetween. The coolant inlet 30 is aligned linearly with the coolant outlet 32. The first fluid inlet 40 is aligned linearly with the first fluid outlet 42. The first fluid channels 44 extend between the first fluid inlet 40 and the first fluid outlet 42. The second fluid inlet 50 is aligned linearly with the second fluid outlet 52. The second fluid channels 54 extend between the second fluid inlet 50 and the second fluid outlet 52. The coolant inlet 30 and the coolant outlet 32 extend perpendicular to the first fluid inlet 40 and the first fluid outlet 42. The coolant inlet 30 and the coolant outlet 32 also extend perpendicular to the second fluid inlet 50 and the second fluid outlet 52. The first fluid inlet 40 and the first fluid outlet 42 extend perpendicular to the second fluid inlet 50 and the second fluid outlet 53. The coolant channels 36, the first fluid channels 44, and the second fluid channels 54 are all intertwined and thereby configured to simultaneously transfer heat between coolant flowing through the coolant channels 36 and each of a first fluid flowing through the first fluid channels 44 and a second fluid flowing through the second fluid channels 54. The shape of the heat exchanger 210, including the positioning of the inlets and the outlets, promotes circulation of the coolant around the various fluid channels thereby making a baffle unnecessary.

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.