Heat exchanger with integrated electrical heating element

Patent metadata

Field	Value
Publication number	US-11938782-B2
Application number	US-201916977796-A
Country	US
Kind code	B2
Filing date	Mar 7, 2019
Priority date	Mar 7, 2018
Publication date	Mar 26, 2024
Grant date	Mar 26, 2024

Abstract

A heat exchanger has a fluid flow passage having an inlet and an outlet, and with a first plate and a second plate in opposed facing relation to one another. The fluid flow passage is defined by a space between the inner surfaces of the first and second plates. An electrical heating element is outside the fluid flow passage and adjacent to the outer surface of the first plate, such that heat produced by the electrical heating element is transferred through the first plate to the fluid in the fluid flow passage during use of the heat exchanger. In an embodiment, the first plate has an opening to receive a heater plate component including a first plate portion having an inner surface bonded to a turbulence-enhancing insert and an outer surface bonded to the electrical heating element.

First claim

What is claimed is:

1. A heat exchanger, comprising:
(a) a fluid flow passage adapted for flow of a fluid, the fluid flow passage having an inlet and an outlet;
(b) a first plate and a second plate in opposed facing relation to one another, wherein each of the first plate and the second plate are thermally conductive, have an inner surface facing inwardly toward the fluid flow passage and an outer surface facing outwardly from the fluid flow passage, wherein the fluid flow passage is defined by a space between the inner surface of the first plate and the inner surface of the second plate;
(c) a first electrical heating element located outside the fluid flow passage and adjacent to the outer surface of the first plate, such that heat produced by the first electrical heating element is transferred through the first plate to the fluid in the fluid flow passage during use of the heat exchanger;
wherein the first electrical heating element has a thickness between 1 μm and about 1000 μm;
wherein the first electrical heating element comprises an electrically insulating dielectric base layer which is closest to the outer surface of the first plate, and an electrically resistive heater layer on the dielectric base layer; and
(d) a heat sink plate having an inner surface which is fixed to the outer surface of the first plate by a metallurgical bond, and an outer surface to which the first electrical heating element is applied with the electrically insulating dielectric base layer of the first electrical heating element in contact with and thermally bonded to the outer surface of the heat sink plate;
wherein the heat sink plate is thicker than either of the first plate and the second plate; and
wherein the electrically insulating dielectric base layer comprises thermally conductive, electrically insulating composite layer comprising a polymer mixed with a particulate filler material.

2. The heat exchanger of claim 1 , wherein the dielectric base layer is in contact with and thermally bonded to the outer surface of the first plate.

3. The heat exchanger of claim 1 , wherein at least one of the first plate and the second plate comprises a shaped plate having a substantially flat, planar base surrounded on all sides by a raised peripheral sidewall extending from the base to a planar flange defining a sealing surface along which the planar flange is sealingly secured to the opposing one of the first plate and the second plate.

4. The heat exchanger of claim 1 , wherein the first electrical heating element further comprises an electrically conductive layer in contact with the resistive heater layer;
wherein the conductive layer comprises one or more conductive strips or buss bars which are adapted to be connected to an electrical power supply; and
wherein the first electrical heating element further comprises an electrically insulating dielectric top layer provided on the resistive heater layer.

5. The heat exchanger of claim 1 , further comprising a turbulence-enhancing insert comprising a corrugated fin or a turbulizer having ridges connected by side walls, wherein a first plurality of said ridges is in contact with the inner surface of the first plate, and wherein the first plurality of said ridges is in thermal contact with the inner surface of the first plate, wherein the turbulence-enhancing insert further comprises a second plurality of said ridges which is in contact with the inner surface of the second plate but is not metallurgically bonded thereto, so as to provide a thermal conductance gap therebetween.

6. The heat exchanger of claim 1 , further comprising:
a second electrical heating element provided outside the fluid flow passage and located adjacent to the outer surface of the second plate, such that heat produced by the second electrical heating element is transferred through the second plate to the fluid in the fluid flow passage during use of the heat exchanger;
wherein the second electrical heating element has a thickness from about 1 μm to about 1000 μm;
wherein the second electrical heating element comprises an electrically insulating dielectric base layer which is closest to the outer surface of the second plate, and an electrically resistive heater layer on the dielectric base layer; and
wherein the dielectric base layer comprises a thermally conductive, electrically insulating composite layer comprising a polymer mixed with a particulate filler material.

7. The heat exchanger of claim 1 , wherein the second plate comprises a shaped plate having a generally flat, planar base surrounded on all sides by a raised peripheral sidewall extending from the base to a planar flange defining a first sealing surface along which the raised peripheral sidewall is sealingly secured to the opposing one of the first plate and the second plate;
wherein the second plate has a plurality of protrusions formed in the flat, planar base thereof, the protrusions having a height which is the same as a height of the planar flange, each said protrusion having a second sealing surface which is co-planar with the first sealing surface of the planar flange;
wherein the second sealing surfaces of the protrusions are in thermal contact with the inner surface of the first plate; and
wherein the protrusions comprise ribs and/or dimples.

8. The heat exchanger of claim 1 , wherein the outer surface of the first plate is substantially flat;
wherein the first electrical heating element is in contact with a substantially flat portion of the outer surface of the first plate;
wherein the first electrical heating element is adapted for contact with and support of a vehicle component; and
wherein the vehicle component comprises at least one battery cell and/or battery module of a rechargeable vehicle battery.

9. The heat exchanger of claim 1 , wherein the outer surface of the second plate is substantially flat;
wherein the outer surface of the second plate is adapted for contact with and support of a vehicle component; and
wherein the vehicle component comprises at least one battery cell and/or battery module of a rechargeable vehicle battery.

10. The heat exchanger according to claim 1 , wherein the heat exchanger comprises a fluid heater for indirect heating of one or more vehicle components which are remote from heat exchanger.

11. The heat exchanger according to claim 1 , wherein at least one of the first electrical heating element and the second electrical heating element has a flat outer surface adapted for thermal contact with one or more vehicle components, for direct heating of the one or more vehicle components.

12. The heat exchanger according to claim 11 , wherein the flat outer surface of at least one of the first electrical heating element and the second electrical heating element is adapted to support said one or more vehicle components; and
wherein said one or more vehicle components comprise one or more battery cells or battery modules of a rechargeable lithium-ion battery for a vehicle.

13. A heat exchanger, comprising:
(a) a fluid flow passage adapted for flow of a fluid, the fluid flow passage having an inlet and an outlet;
(b) a first plate and a second plate in opposed facing relation to one another, wherein each of the first plate and the second plate are thermally conductive, have an inner surface facing inwardly toward the fluid flow passage and an outer surface facing outwardly from the fluid flow passage, wherein the fluid flow passage is defined by a space between the inner surface of the first plate and the inner surface of the second plate; and
(c) a first electrical heating element located outside the fluid flow passage and adjacent to t

Assignees

• Dana Canada Corp

Inventors

• Cheadle Brian E
• Bardeleben Michael J R
• Sheppard Jeffrey O
• Kenney Benjamin A

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• B60H1/00278 Primary

  for the battery · CPC title

• F24H1/105

  formed by the tube through which the fluid flows · CPC title

• F28F3/12

  Elements constructed in the shape of a hollow panel, e.g. with channels {(F28D1/02, F28D1/03 take precedence)} · CPC title

• H05B3/262 Primary

  the insulating base being an insulated metal plate · CPC title