A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.

An exhaust gas recirculation (EGR) cooler includes: a housing having an exhaust gas inlet and an exhaust gas outlet, a coolant inlet and a coolant outlet, and a plurality of grooves protruding inward from upper and lower surfaces of the housing; a plurality of tubes spaced apart from each other so that exhaust gas flows in the housing; and a plurality of supporters supporting the plurality of tubes in the housing, wherein the plurality of supporters are disposed between an upper surface of the housing and a tube adjacent the upper surface of the housing among the plurality of tubes, between an lower surface of the housing and a tube adjacent the lower surface of the housing among the plurality of tubes, and between the plurality of tubes so that the plurality of supporters are disposed in a space in which the coolant flows inside the housing.

A heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers housing one or more battery cells. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages providing a counter-flow heat exchanger. In some embodiments the heat exchanger has two pairs of inlet and outlet manifolds, the heat exchanger providing a single-pass, counter-flow arrangement. In other embodiments the first and second fluid flow passages are interconnected by turn portions forming a U-flow, counter-flow heat exchanger.

A plate stack structure including plate stacks is disclosed. The plate stack structure according to the present invention includes: a base; a plurality of plate stacks having a predetermined shape; a plurality of fixing parts for fixing the plate stacks, respectively; a cover coupled to an end surface of an edge of the base, the cover holding the plate stacks therein; and a support plate commonly placed in the plate stacks, the support plate coming into contact with an inner surface of the cover.

One example aspect of the present disclosure is directed to a system for cooling a surface. The system can include a housing. The housing can include an evaporator portion. The housing can include at least one trifurcated heat exchange portion. The at least one trifurcated heat exchange portion can include a condenser portion coupled to the evaporator portion. The at least one trifurcated heat exchange portion can include a coolant portion substantially surrounded by the condenser portion. The at least one trifurcated heat exchange portion can include a phase change material portion substantially surrounding the condenser portion.

A charge air cooler, e.g., as used with a supercharger having meshing rotors in sealing contact with a housing, the housing having an inlet port to admit air into the meshing rotors and the housing having an outlet port to expel air from the meshing rotors, the charge air cooler having an inlet-side core for transmitting the flow of pressurized air, and an outlet-side core receiving the flow of pressurized air transmitted from the inlet-side core and further transmitting the flow of pressurized air, each core having coolant conduits and fins joined to the coolant conduits for contact with the flow of pressurized air, the fins being arranged with a predetermined density, wherein the inlet-side core fin density is lower than the outlet-side core fin density, whereby the inlet-side core presents less resistance to the flow of pressurized air than the outlet-side core and the outlet-side core presents greater surface area for heat conductance from the flow of pressurized air than the inlet-side core. Charge air coolers with this configuration provide improved pressure and temperature characteristics in a supercharger's flow of pressurized air to an engine.

One example aspect of the present disclosure is directed to a system for cooling a surface. The system can include a housing. The housing can include an evaporator portion. The housing can include at least one trifurcated heat exchange portion. The at least one trifurcated heat exchange portion can include a condenser portion coupled to the evaporator portion. The at least one trifurcated heat exchange portion can include a coolant portion substantially surrounded by the condenser portion. The at least one trifurcated heat exchange portion can include a phase change material portion substantially surrounding the condenser portion.

A water-cooling radiator structure with internal partition member includes a water-cooling radiator unit, which includes a first water-receiving plate defining a first inner space and having a water inlet and a water outlet fluid-communicable with the first inner space. A working fluid flows into the first inner space via the water inlet and leaves the first inner space via the water outlet. The first inner space is internally provided with at least one first partition member, which horizontally divides the first inner space into a plurality of independent water chambers, so that the working fluid sequentially flow through the water chambers.

A heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers housing one or more battery cells is disclosed. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages providing a counter-flow heat exchanger. In some embodiments the heat exchanger has a two pairs of inlet and outlet manifolds, the heat exchanger providing a single-pass, counter-flow arrangement. In other embodiments the first and second fluid flow passages are interconnected by turn portions forming a U-flow, counter-flow heat exchanger.

Apparatus, systems, and methods for a modular heating unit that may be adapted to be inline with a pipeline. The unit includes a base member having a main inlet pipe, a header, and pipes connecting the main inlet pipe with the header. A combustion chamber is positioned within the pipes. One or more heat exchangers are connected to the header. The heat exchangers each having a top surface, bottom surface, plurality of fins, inlet ring, inlet port, outlet ring, and outlet port. The modular heating unit includes external inlet and outlet pipes. A first flow path enables fluid to flow from the header into the one or more heat exchangers. An exit flow path connected to the external outlet pipe connects the one or more heat exchangers to an exit port with a portion of the exit flow path being positioned above the one or more heat exchangers.