Heat exchanger with internal manifold structure

1. A heat exchanger, comprising:

a first plate having an inner surface and an outer surface;

a second plate having an inner surface and an outer surface, wherein the first and second plates are disposed with their inner surfaces in opposed facing relation to one another and with portions of the inner surfaces being spaced apart from one another;

a manifold region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another for receiving an incoming heat transfer fluid;

a main fluid flow region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another, the main fluid flow region configured for receiving heat transfer fluid from an outlet end of the manifold region and transmitting the heat transfer fluid through the heat exchanger, the main fluid flow region includes a fluid flow passage comprising a plurality of fluid flow passage portions extending generally transverse to a central, longitudinal axis of the heat exchanger wherein each fluid flow passage portion is fluidically interconnected to an adjacent fluid flow passage portion by a turnaround zone such that each fluid flow passage portion defines a flow direction, wherein the flow direction of one of the plurality of fluid flow passage portions is opposite to the flow direction of an adjacent one of the plurality of fluid flow passage portions, the plurality of fluid flow passage portions each have a width, the width of a first fluid flow passage portion of the plurality of fluid flow passage portions being less than the width of remaining ones of the plurality of fluid flow passage portions;

an inlet port disposed in fluid communication with an inlet end of the manifold region for supplying the heat transfer fluid to the heat exchanger;

an outlet port disposed in fluid communication with the main fluid flow region for discharging the heat transfer fluid from the heat exchanger;

wherein the manifold region includes:

a first manifold fluid distribution channel having a first end in fluid communication with the inlet port and a second end in fluid communication with the main fluid flow region; and

a second manifold fluid distribution channel separate from and extending parallel to, or substantially parallel to, the first manifold fluid distribution channel, the second manifold fluid distribution channel having a first end in fluid communication with the inlet port and a second end in fluid communication with the main fluid flow region; and

at least one bypass port for establishing fluid communication between the manifold region and the main fluid flow region at a location within the manifold region that is upstream of the second end of the manifold region, wherein the at least one bypass port is disposed in fluid communication with the second manifold fluid distribution channel.

2. The heat exchanger as claimed in claim 1 , wherein:

the manifold region extends along an axis parallel to, or substantially parallel to the central, longitudinal axis of the heat exchanger between the inlet end of the manifold region in fluid communication with the inlet port and the outlet end of the manifold region wherein the outlet end of the manifold region is in fluid communication with a first fluid flow passage portion of the plurality of fluid flow passage portions.

3. The heat exchanger as claimed in claim 1 , comprising:

a first bypass port establishing fluid communication between the manifold region and the main fluid flow region at a location within the manifold region that is upstream of the outlet end of the manifold region; and

a second bypass port establishing fluid communication between the manifold region and the main fluid flow region at a location intermediate the first bypass port and the outlet end of the manifold region.

4. The heat exchanger as claimed in claim 1 , wherein the first fluid flow passage portion width is less than 15% of an overall length of the heat exchanger.

5. The heat exchanger as claimed in claim 1 , wherein the at least one bypass port has a minimum length of at least 10 mm and a maximum length of 25 mm.

6. The heat exchanger as claimed in claim 1 , wherein the heat exchanger is a cold plate heat exchanger adapted to support a plurality of battery cells on the outer surface of the first plate.

7. The heat exchanger as claimed in claim 6 , further comprising a layer of thermal interface material (TIM) disposed on the outer surface of the first plate, wherein the plurality of battery cells are disposed in thermal contact with the thermal interface material when the plurality of battery cells are supported on the outer surface of the first plate.

8. A heat exchanger, comprising:

a first plate having an inner surface and an outer surface;

a second plate having an inner surface and an outer surface, wherein the first and second plates are disposed with their inner surfaces in opposed facing relation to one another and with portions of the inner surfaces being spaced apart from one another;

a manifold region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another for receiving an incoming heat transfer fluid;

a main fluid flow region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another, the main fluid flow region comprising a plurality of fluid flow passage portions extending generally transverse to a central, longitudinal axis of the heat exchanger wherein each fluid flow passage portion is fluidically interconnected to an adjacent fluid flow passage portion by a turnaround zone such that each fluid flow passage portion defines a flow direction, wherein the flow direction of one of the plurality of fluid flow passage portions is opposite to the flow direction of an adjacent one of the plurality of fluid flow passage portions, wherein the main fluid flow region configured for receiving heat transfer fluid from an outlet end of the manifold region and transmitting the heat transfer fluid through the heat exchanger, wherein the plurality of fluid flow passage portions include:

a first fluid flow passage portion in fluid communication with the outlet end of the manifold region, the first fluid flow passage portion defining a first fluid flow passage portion width;

a last fluid flow passage portion in fluid communication outlet port, the last fluid flow passage portion defining a last fluid flow passage portion width; and

one or more intermediate fluid passage portions disposed between the first fluid flow passage portion and the last fluid flow passage portion, each one of the one or more intermediate fluid passage portions defining an intermediate fluid passage portion width;

wherein the first fluid flow passage portion width is less than the last fluid flow passage portion width and less than each of the intermediate fluid passage portion widths;

an inlet port disposed in fluid communication with an inlet end of the manifold region for supplying the heat transfer fluid to the heat exchanger; and

an outlet port disposed in fluid communication with the main fluid flow region for discharging the heat transfer fluid from the heat exchanger;

wherein the manifold region includes at least one bypass port for establishing fluid communication between the manifold region and the main fluid flow region at a location within the manifold region that is upstream of the second end of the manifold region.

9. The heat exchanger as claimed in claim 8 , wherein the last fluid flow passage portion width is greater than the first fluid flow passage portion width and less than each of the intermediate fluid passage portion widths.

10. A heat exchanger, comprising:

a first plate having an inner surface and an outer surface;

a second plate having an inner surface and an outer surface, wherein the first and second plates are disposed with their inner surfaces in opposed facing relation to one another and with portions of the inner surfaces being spaced apart from one another, and wherein the second plate is a shaped plate comprising a generally flat, planar base portion surrounded by a raised peripheral sidewall, the peripheral sidewall extending from the base portion to a planar flange,

wherein the planar flange includes a peripheral sealing surface, such that when the first and second plates are disposed in mating relationship with their inner surfaces in opposed facing relation to one another, the peripheral sealing surface of the second plate is sealingly joined to the inner surface of the first plate;

a manifold region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another for receiving an incoming heat transfer fluid;

a main fluid flow region enclosed between the first and second plates and disposed between portions of the inner surfaces that are spaced apart from one another, the main fluid flow region configured for receiving heat transfer fluid from an outlet end of the manifold region and transmitting the heat transfer fluid through the heat exchanger, the main fluid flow region includes a plurality of fluid barrier ribs, each one of the plurality of fluid barrier ribs extending transverse to, or substantially transverse to, the central longitudinal axis of the heat exchanger and being spaced apart from each other and offset with respect to one another along an axis parallel to, or substantially parallel to, the central longitudinal axis of the heat exchanger, the plurality of fluid barrier ribs include a first set fluid barrier ribs having a first end merged with a portion of the manifold rib and a second end spaced apart from a corresponding portion of the peripheral sidewall of the second plate that defines a side edge of the heat exchanger opposite to the manifold region and a second set of fluid barrier ribs having a first end disposed proximal to the peripheral sidewall of the second plate that defines the side edge of the heat exchanger opposite to the manifold region, and a second end spaced apart from the manifold rib, the first set of fluid barrier ribs alternate with the second set of fluid barrier ribs defining a multipass fluid flow passage through the main fluid flow region of the heat exchanger;

an inlet port disposed in fluid communication with an inlet end of the manifold region for supplying the heat transfer fluid to the heat exchanger;

an outlet port disposed in fluid communication with the main fluid flow region for discharging the heat transfer fluid from the heat exchanger; and

a manifold rib that extends outwardly from the generally flat, planar base portion of the second plate such that an upper surface of the manifold rib is disposed co-planar with, or substantially co-planar with the peripheral sealing surface of the peripheral flange of the second plate, the manifold rib extending parallel to, or substantially parallel to a central longitudinal axis of the heat exchanger, the manifold rib fluidically separating portions of the manifold region from the main fluid flow region;

wherein the manifold region includes at least one bypass port for establishing fluid communication between the manifold region and the main fluid flow region at a location within the manifold region that is upstream of the second end of the manifold region.

11. The heat exchanger as claimed in claim 10 , wherein the manifold rib includes a plurality of manifold rib portions, wherein the manifold rib portions are spaced apart from each other forming the at least one bypass port.

12. The heat exchanger as claimed in claim 10 , wherein a first bypass port is located downstream from a last one of the plurality of fluid barrier ribs by a first predetermined distance along an axis parallel to, or substantially parallel to, the central longitudinal axis of the heat exchanger.

13. The heat exchanger as claimed in claim 12 , wherein a second bypass port is located downstream from one of the plurality of fluid barrier ribs upstream from the last one of the plurality of fluid barrier ribs by a second predetermined distance along an axis parallel to, or substantially parallel to, the central longitudinal axis of the heat exchanger.

14. The heat exchanger as claimed in claim 10 , wherein the generally flat, planar base portion includes a plurality of surface protrusions extending out of the planar base portion.