MAL-DISTRIBUTION IN PLATE FIN HEAT EXCHANGER

CROSS-REFERENCE TO RELATED APPLICATION

[0001]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.

FIELD

[0002]The disclosure relates to a heat exchanger, and more particularly to a plate heat exchanger with improved flow distribution.

BACKGROUND

[0003]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.

[0004]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.

[0005]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.

SUMMARY

[0006]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.

[0007]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.

[0008]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.

[0009]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.

[0010]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.

[0011]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.

[0012]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.

[0013]As aspects of some embodiments, one or more of the flow channels is a vertical flow channel or a horizontal flow channel.

[0014]As aspects of some embodiments, the flow diverter is formed by deforming at least a portion of one or more of the flow channels.

[0015]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.

[0016]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.

[0017]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.

[0018]As aspects of some embodiments, the sheet is a stamped sheet formed from a metal material.

[0019]As aspects of some embodiments, the flow diverter is formed in the sheet more proximate the inflow opening than the outflow opening.

[0020]As aspects of some embodiments, the flow diverter is formed in the sheet more proximate the outflow opening than the inflow opening.

[0021]As aspects of some embodiments, the flow diverter is formed in a center portion of the sheet.

[0022]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.

[0023]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.

[0024]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.

[0025]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.

[0026]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.

[0027]As aspects of some embodiments, the flow diverter extends vertically or horizontally across at least half of the sheet.

[0028]As aspects of some embodiments, the flow diverter extends vertically or horizontally across less than half of the sheet.

[0029]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

[0030]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.

[0031]FIG. 1 is a schematic diagram of a thermal management system including at least one heat exchanger accordance with an embodiment of the presently described subject matter;

[0032]FIG. 2 is a schematic, partially exploded perspective view of a heat exchanger in accordance with an embodiment of the presently described subject matter, wherein the heat exchanger includes a plurality of plates and a plurality of thermal energy transfer devices;

[0033]FIG. 3 is a schematic elevational view of one of the plates provided with one of the thermal energy transfer devices of FIG. 2;

[0034]FIG. 4 is a bottom perspective view of a thermal energy transfer device provided with a flow diverter for a first fluid according to an embodiment of the present disclosure;

[0035]FIG. 5 is an enlarged, fragmentary bottom perspective view of a portion of the thermal energy transfer device of FIG. 4 showing the flow diverter;

[0036]FIG. 6 is a schematic elevational view of one of the plates provided with a thermal energy transfer device for the first fluid according to another embodiment of the present disclosure;

[0037]FIG. 7 is a bottom perspective view of a thermal energy transfer device provided with a flow diverter for a second fluid according to another embodiment of the present disclosure; and

[0038]FIG. 8 is a bottom perspective view of a thermal energy transfer device provided with a flow diverter for the second fluid according to yet another embodiment of the present disclosure;

DETAILED DESCRIPTION

[0039]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.

[0040]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.

[0041]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.

[0042]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.

[0043]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.

[0044]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.

[0045]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.

[0046]FIG. 1 illustrates a thermal management system 2 generally. As depicted, the thermal management system 2 may include one or more plate heat exchangers 10 according to embodiments of the present disclosure and described hereinafter. In some embodiments, the heat exchangers 10 may perform as an evaporator and/or a condenser. The heat exchangers 10 may be fluidly connected and/or in fluid communication with a first circuit 14 for a first fluid (e.g., a refrigerant) and a second circuit 16 for a second fluid (e.g. a coolant). It is understood that each of the second circuits 16 shown 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 10. 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 exchangers 10 being integrated into the first circuit 14 and the second circuit 16 permits a transfer of thermal energy between the first fluid and the second fluid. In preferred embodiments, the heat exchangers 10 that perform as a condenser permit the first fluid to be at least partially condensed by the second fluid and the heat exchangers 10 that perform as an evaporator permit the first fluid to be at least partially vaporized by the second fluid.

[0047]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.

[0048]FIG. 2 illustrates the heat exchanger 10 according to the present disclosure. In the embodiment depicted, a plurality of first plates 30 (i.e., A-plates) and a plurality of second plates 32 (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 assembly 10 between the opposing end plates 34, 36. In other embodiments, when the second plates 32 are of a different design than the first plates 30 (i.e., B-plates), the heat exchanger 10 may comprise a plurality of first plates 30 and a plurality of second plates 32 alternatingly 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 34, 36. It is understood that one or more of the end plates 34, 36 may be part of a housing of the heat exchanger 10 if desired. It is understood, however, that the heat exchanger 10 may include any number of the plates 30, 32 as desired.

[0049]Inlet ports 38, 40, and corresponding outlet ports 42, 44, for each of the first and second circuits 14, 16, respectively, are formed in one of the end plates 34, 36. In some embodiments, the inlet ports 38, 40, and the outlet ports 42, 44, are integrally formed with the one of the end plates 34, 36, yet in other embodiments they are formed as separate and distinct components that are coupled to the one of the end plates 34, 36. Each of the first and second plates 30, 32 and/or each of the end plates 34, 36 may be substantially elongate and rectangular. However, it is understood that the first and second plates 30, 32 and the end plates 34, 36 may have various shapes, sizes, and configurations as desired. In certain embodiments, the plates 30, 32 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 FIG. 2, the heat exchanger 10 is 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 exchanger 10 is opposite a direction of flow of the second fluid through the heat exchanger 10. It is understood that the plates 30, 32 and respective inlet ports 38, 40 and outlet ports 42, 44 may be so that the direction of flow of the first fluid through the heat exchanger 10 is the same as the direction of flow of the second fluid through the heat exchanger 10.

[0050]In preferred embodiments, the first plate 30 includes an inflow opening 46 and an outflow opening 48 formed therein and the second plate 32 includes an inflow opening 50 and an outflow opening 52. The inflow openings 46, 50 may be fluidly connected to the inlet ports 38, 40, respectively, and the outflow openings 48, 52 may be fluidly connected to the outlet ports 42, 44, respectively. The inflow openings 46, 50 and the outflow openings 48, 52 may be located in opposite corners of the respective first and second plates 30, 32. Accordingly, the first and second fluids may flow from the inflow openings 46, 50, through a substantial portion or across an entirety of the heat exchanger 10 to the outflow openings 48, 52, thereby a distance from the inflow openings 46, 50 to the outflow openings 48, 52 that the first and second fluids have to travel may be maximized.

[0051]In the embodiment shown, each of the first plates 30 may further include one or more shaped sections 54 formed therein. Each of the shaped section 54 surrounds a periphery of flow openings 56, 58 formed in the first plate 30 and abuts a first surface 60 of the second plate 32 to militate against leakage of the first fluid into the second flow paths and the second fluid into the first flow path.

[0052]In the embodiment shown, each of the second plates 32 may further include one or more shaped section 62 formed therein. Each of the shaped section 62 surrounds a periphery of flow openings 64, 66 formed in the second plate 32 and abuts a first surface 68 of the adjacent first plate 30 to militate against leakage of the second fluid into the first flow paths and the first fluid into the second flow path.

[0053]It is understood that each of the openings 46, 48, 50, 52, 56, 58, 64, 66 may be located elsewhere in the respective first and second plates 30, 32 to achieve a desired thermal energy exchange between the first fluid and the second fluid.

[0054]The first flow path and the second flow path are formed alternately between the plates 30, 32 and the end plates 34, 36. The openings 46, 64 of the plates 30, 32, respectively, are fluidly connected to form an inlet manifold for the first fluid, which is fluidly coupled to the inlet port 38, and the openings 48, 66 of the plates 30, 32, respectively, are fluidly connected to form an outlet manifold for the first fluid, which is fluidly coupled to the outlet port 42. As such, the first fluid of the first circuit 12 flows into the inlet port 38, through the inlet manifold and the associated first flow paths defined by the plates 30, 32 where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet manifold, and from the outlet port 42 back into the first circuit 12. Similarly, the openings 50, 56 of the plates 32, 30, respectively, are fluidly connected to form an inlet manifold for the second fluid, which is fluidly coupled to the inlet port 40, and the openings 52, 58 of the plates 32, 30, respectively, are fluidly connected to form an outlet manifold for the second fluid, which is fluidly coupled to the outlet port 44. As such, the second fluid of the second circuit 14 flows into the inlet port 40, through the inlet manifold and the associated second flow paths defined by the plates 30, 32 where an exchange of thermal energy occurs between the first fluid and the second fluid, through the outlet manifold, and from the outlet port 44 back into the second circuit 14.

[0055]At least one thermal energy transfer device 70 (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 device 70 may be configured to improve fluid flow distribution with the heat exchanger 10 and 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 10. As best shown in FIG. 2, the heat exchanger 10 includes one or more thermal energy transfer devices 70 disposed between the first and second plates 30, 32. In some embodiments, at least one of the thermal energy transfer devices 70 is disposed in the first flow path for the first fluid between the first and second plates 30, 32. In other embodiments, one or more of the thermal energy transfer devices 70 (shown in FIGS. 4-6) is disposed in the first flow path for the first fluid between the first and second plates 30, 32 and/or one or more thermal energy transfer devices 71 (shown in FIGS. 7 and 8) is disposed in the second flow path for the second fluid between the first and second plates 30, 32. It is understood that the thermal energy transfer device 71 may be the thermal energy transfer device 70 rotated 180 degrees or vertically reflected with respect to a horizontal axis.

[0056]The thermal energy transfer device 70 may include an inflow opening 72 and an outflow opening 74 formed therein to permit the flow of the first fluid therethrough and one or more openings 76 formed therein to accommodate the shaped sections 54. Similarly, the thermal energy transfer device 71 may include an inflow opening 78 and an outflow opening 80 formed therein to permit the flow of the second fluid therethrough and one or more openings 82 formed therein to accommodate the shaped sections 62. It is understood, however, that the heat exchanger 10 may include any number, or none, of the thermal energy transfer devices 70, 71 as desired.

[0057]FIGS. 3-5 illustrate an exemplary embodiment of the thermal energy transfer device 70 having a flow diverter 88 for the first fluid according to the present disclosure. As best seen in FIG. 4, the thermal energy transfer device 70 comprises a sheet 90. It is understood that the sheet 90 may 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 sheet 90 has a generally serpentine and/or crenelated cross-sectional shape. It is understood, however, that the sheet 90 may have any suitable cross-sectional shape, size, and configuration as desired.

[0058]As shown, the sheet 90 has a plurality of protuberances 92 (e.g., fins, ribs, etc.), which define a plurality of flow channels 96. In some embodiments, one or more of the flow channels 96 may be formed at an angle to the direction of flow of the first fluid through the heat exchanger 10. In a non-limiting example, one or more of the flow channels 96 may be formed substantially perpendicular to the direction of flow of the first fluid through the heat exchanger 10 and/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device 70. Thus, the flow channels 96 shown may be generally vertical flow channels. It is understood, however, that the flow channels 96 may be generally horizontal flow channels depending on an orientation of the heat exchanger 10. One of more of the flow channels 96 may extend across an entirety of the sheet 90 from one longitudinal edge to an opposite longitudinal edge thereof. As best seen in FIG. 5, one or more of the flow channels 96 may be fluidly connected to one or more adjacent flow channels 96 by one or more fluid passageways 98 (i.e., windows) formed in the sheet 90. In other embodiments, the flow channels 96 may be generally horizontal flow channels, extending across an entirety of the sheet 90 from one lateral edge to an opposite lateral edge.

[0059]As depicted in FIGS. 3 and 6, the flow diverter 88 may be configured to prevent the flow of the first fluid through a certain portion of the fluid passageways 98, which causes the flow of the first fluid to be diverted. In some embodiments, the flow diverter 88 may be formed at an angle to the direction of flow of the first fluid through the heat exchanger 10. In a non-limiting example, the flow diverter 88 may be formed substantially perpendicular to the direction of flow of the first fluid through the heat exchanger 10 and/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device 70. As depicted, the flow diverter 88 has a generally linear shape and configuration extending from a lower portion and/or a longitudinal edge portion of the sheet 90 to a center portion and/or an opposite longitudinal edge portion thereof. In other embodiments, the flow diverter 88 may extend from a lateral edge portion of the sheet 90 to a center portion and/or an opposite lateral edge portion thereof. In some instances, the flow diverter 88 may extend vertically or horizontally across at least half of the sheet 90. In other instances, the flow diverter may extend vertically or horizontally across less than half of the sheet 90. It is understood, however, the flow diverter 88 may have any suitable shape, size, and configuration as desired to achieve improved flow distribution of the first fluid within the heat exchanger 10.

[0060]In the embodiments shown, the flow diverter 88 is formed in the sheet 90 between the inflow opening 72 and the outflow opening 74. In the embodiment depicted in FIGS. 2-5, the flow diverter 88 may be formed in the sheet 90 more proximate the inflow opening 72 than the outflow opening 74. Thus, the flow diverter 88 causes a generally horizontal P-shaped flow of the first fluid within the heat exchanger 10. This generally horizontal P-shaped flow may be particularly beneficial in low flow conditions of the first fluid, where the first fluid must travel to an upper portion of the thermal energy transfer device 70 as soon as possible to fully utilize an entirety of the heat transfer surface area thereof. In such configuration, as the first fluid flows across the heat exchanger 10, gravity causes the first fluid to flow downward. Thus, a full length of the protuberances 92 and the flow channels 96 needs to be utilized. In other embodiments shown in FIG. 6, the flow diverter 88 may be formed in a center portion of the sheet 90, which causes a generally inverted U-shaped flow of the first fluid within the heat exchanger 10. As depicted in FIGS. 3 and 6, the vertical flow channels 96 and the flow diverter 88 causes the first fluid to flow from the inflow opening 72 upwards against gravity and then across the heat exchanger 10 to the outflow opening 74.

[0061]It should also be appreciated that the thermal energy transfer device 70 provided with the flow diverter 88 is particularly critical in heat pump conditions where the heat exchanger 10 performs as a chiller and the flow of the first fluid is extremely low due to operating conditions. A decrease in chiller performance adversely affects a mass flow of the thermal management system 2, which also decreases a condenser performance that drives heating performance. Accordingly, the thermal energy transfer device 70 provided with the flow diverter 88 improves mal-distribution and greatly increases the performance of the heat exchanger 10 without changing locations of the inlet and outlet ports 38, 42 and/or needing a complex multi-pass or cross-flow design. Thus, a complexity of the heat exchanger 10 and component requirements are minimized.

[0062]FIGS. 7-8 illustrate exemplary embodiments of the thermal energy transfer device 71 having a flow diverter 99 for the second fluid according to the present disclosure. Similar to the thermal energy transfer device 70, the thermal energy transfer device 71 comprises a sheet 100. It is understood that the sheet 100 may 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 sheet 100 has a generally serpentine and/or crenelated cross-sectional shape. It is understood, however, that the sheet 100 may have any suitable cross-sectional shape, size, and configuration as desired.

[0063]As shown, the sheet 100 has a plurality of protuberances 102 (e.g., fins, ribs, etc.), which define a plurality of flow channels 106. In some embodiments, one or more of the flow channels 106 may be formed at an angle to the direction of flow of the second fluid through the heat exchanger 10. In a non-limiting example, one or more of the flow channels 106 may be formed substantially perpendicular to the direction of flow of the second fluid through the heat exchanger 10 and/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device 71. Thus, the flow channels 106 shown may be generally vertical flow channels. It is understood, however, that the flow channels 106 may be generally horizontal flow channels depending on an orientation of the heat exchanger 10. One of more of the flow channels 106 may extend across an entirety of the sheet 100 from one longitudinal edge to an opposite longitudinal edge thereof. One or more of the flow channels 106 may also be fluidly connected to one or more adjacent flow channels 106 by one or more fluid passageways 108 (i.e., windows) formed in the sheet 100.

[0064]In accordance with the present disclosure, the flow diverter 99 may be configured to prevent the flow of the second fluid through a certain portion of the fluid passageways 108, which causes the flow of the second fluid to be diverted. In some embodiments, the flow diverter 99 may be formed at an angle to the direction of flow of the second fluid through the heat exchanger 10. In a non-limiting example, the flow diverter 99 may be formed substantially perpendicular to the direction of flow of the second fluid through the heat exchanger 10 and/or substantially perpendicular to a longitudinal axis of the thermal energy transfer device 71. As depicted, the flow diverter 99 has a generally linear shape and configuration extending from an upper portion and/or a longitudinal edge of the sheet 100 to a center portion thereof. It is understood, however, the flow diverter 99 may have any suitable shape, size, and configuration as desired to achieve improved flow distribution of the second fluid within the heat exchanger 10.

[0065]In the embodiments shown, the flow diverter 99 is formed in the sheet 100 between the inflow opening 78 and the outflow opening 80. In the embodiment depicted in FIG. 7, the flow diverter 99 may be formed in the sheet 100 more proximate the inflow opening 78 than the outflow opening 80. Thus, the flow diverter 88 causes a generally horizontal inverted and reflected P-shaped flow of the second fluid within the heat exchanger 10. In other embodiments shown in FIG. 8, the flow diverter 99 may be formed in the sheet 100 more proximate the outflow opening 80 than the inflow opening 78, which causes a generally horizontal inverted P-shaped flow of the second fluid within the heat exchanger 10. In yet other embodiments (not depicted), the flow diverter 99 may be formed in a center portion of the sheet 100, which causes a generally U-shaped flow of the second fluid within the heat exchanger 10.

[0066]It should be appreciated that the flow diverters 88, 99 may be formed by any suitable forming method. In certain embodiments, one or more of the flow diverters 88, 99 may be formed by either adding a punch or modifying the stamping processes used to form the thermal energy transfer devices 70, 71. In some embodiments, one or more of the flow diverters 88, 99 may be formed by deforming at least a portion of one or more of the flow channels 96, 106. In a non-limiting example, one or more of the flow diverters 88, 99 may be formed by stamping at least a portion of one or more of the flow channels 96, 106. It is understood, however, that other various processes and methods may be used to deform at least a portion of one or more of the flow channels 96, 106 to form one or more of the flow diverters 88, 99 if desired.

[0067]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.