Heat exchanger

Abstract

A heat exchanger includes a core (110) and a housing (122) that contains the core (110). The core (110) includes a plurality of sets of tubular elements (112a, 112b) and fluid flow channels (116). The fluid flow channels (116) sandwich at least one set of tubular elements (112a, 112b). The housing (122) includes first and second portions (122a) and (122b) and extending ribs (124a) and (124b) that extend from at least one of first and second faces (122c) and (122d), respectively. In an assembled configuration, the extending ribs (124a) and (124b) restrict fluid flow through a gap between the core (110) and the housing (122). At least one of first and second fins (118a) and (118b) disposed in respective first and second fluid flow channels (116a) and (116b) at an end of the core (110) is deformed to interrupt fluid flow through the respective first and second fluid flow channels (116a) and (116b).

Description

Technical Field

[0001] This invention relates to a heat exchanger, and more specifically, to a cooler for cooling batteries in electric vehicles. Background Technology

[0002] As vehicles evolve towards hybrid and pure electric vehicles, there is a need to cool the power electronics and battery packs that power these vehicles, as well as the heating, ventilation, and air conditioning (HVAC) systems used in these vehicles. Therefore, heat exchangers, especially coolers, are required. Depending on the need, coolers are used for at least one of battery cooling or cooling of power electronics-based components.

[0003] Coolers typically handle a first heat exchange fluid, particularly a refrigerant, and a second heat exchange fluid, particularly a coolant, and are constructed as a refrigerant circuit disposed between a pair of coolant circuits. More specifically, the refrigerant circuit is in the form of multiple sets of tubular elements that form fluid flow channels for the first heat exchange fluid, particularly the refrigerant, and are sandwiched between the coolant flow channels. The cooler includes a core formed by arranging the coolant flow channels relative to the multiple sets of tubular elements. The coolant flow channels are arranged relative to the sets of tubular elements such that at least one set of tubular elements is sandwiched between the pair of coolant flow channels. The coolant flow channels are also formed with finned elements to prevent flow through the coolant flow channels and to facilitate heat transfer between the coolant flowing through the coolant flow channels and the refrigerant flowing through the tubular elements. In particular, after heat is extracted from the battery pack of an electric vehicle or any other heat-generating system, the coolant is directed to flow through the coolant flow channels, where the coolant is cooled by heat exchange with the refrigerant flowing through the refrigerant circuit. The cooled coolant is directed to the battery pack or heating system to draw heat from the battery pack again, thus ensuring a regular supply of cooled coolant to the battery pack. Regular cooling of the battery pack prevents damage due to overheating and ensures its efficient operation.

[0004] Typically, each of the first and second coolant flow channels located at the end of the core contacts only one set of tubular elements located on one side. Therefore, the coolant flowing through each of the first and second coolant flow channels exchanges heat with the refrigerant flowing only through the set of tubular elements forming part of the refrigerant circuit. Specifically, the coolant flowing through each of the first and second coolant flow channels exchanges heat only from one side, and this heat exchange is inefficient. In contrast, each centrally located coolant flow channel contacts two sets of tubular elements, one on each side. Therefore, the coolant flowing through each centrally located coolant flow channel can exchange heat with the refrigerant flowing through two adjacent sets of tubular elements, each set of tubular elements located on opposite sides and forming part of the refrigerant circuit. Specifically, the coolant flowing through each centrally located coolant flow channel exchanges heat from both sides, and this heat exchange is efficient.

[0005] Due to the inherent structure of the core, the second heat exchange fluid passes through the first and second coolant flow channels at the ends of the core, thus reducing the flow of the second heat exchange fluid through the centrally located coolant flow channel and adversely affecting the heat exchange efficiency and performance of the cooler. Furthermore, the second heat exchange fluid contained in the shell bypasses the core through the gap between the core and the shell, further negatively impacting heat exchange. If the gap between the core and the shell is primarily due to tolerances in the welding between plastic components, leakage problems between the core and the shell are exacerbated. This construction of conventional coolers leads to reduced efficiency and performance. Few existing technologies suggest using foam in the gap between the core and the shell to prevent leakage from this gap; however, such an arrangement is complex and requires additional components such as foam.

[0006] Therefore, a cooler is needed that enables effective heat exchange between a first heat exchange fluid, particularly a refrigerant flowing through multiple sets of tubular elements forming part of a refrigerant circuit, and a second heat exchange fluid flowing through a flow channel sandwiching at least one set of tubular elements and forming part of the refrigerant circuit. Furthermore, a cooler is needed that incorporates a sealing device for achieving a seal between a housing and a core housed within the housing to prevent the second heat exchange fluid from bypassing the core. Additionally, a cooler is needed that incorporates a sealing device for achieving a seal between the housing and the core without requiring additional components such as foam. Furthermore, a cooler is needed that incorporates means for restricting the flow of the second heat exchange fluid through first and second refrigerant flow channels located at the ends of the core. Furthermore, a cooler is needed that incorporates means for facilitating the flow of the second heat exchange fluid through a refrigerant flow channel located relative to the center of the core. Finally, a cooler is needed that includes means for sealing the gap between the core and the housing, wherein the means is simple in structure, comprises fewer components, is reliable, and inexpensive. Summary of the Invention

[0007] One object of the present invention is to provide a cooler that eliminates the disadvantages associated with other coolers.

[0008] Another object of the present invention is to provide a cooler that achieves improved heat exchange between a first heat exchange fluid, particularly a refrigerant flowing through multiple sets of tubular elements forming part of a refrigerant circuit, and a second heat exchange fluid flowing through a flow channel sandwiching at least one set of tubular elements and forming part of a refrigerant circuit.

[0009] Another object of the present invention is to provide a cooler having a sealing device for achieving a seal between a housing and a core housed within the housing, so as to prevent a second heat exchange fluid from bypassing the core.

[0010] Another object of the present invention is to provide a cooler having a sealing device for achieving a seal between the housing and the core without requiring additional components such as foam to achieve the seal.

[0011] Another object of the present invention is to provide a cooler having means for restricting the flow of a second heat exchange fluid through first and second coolant flow channels located at the end of the core.

[0012] Another object of the present invention is to provide a cooler having means for facilitating the flow of a second heat exchange fluid through a coolant flow channel disposed relative to the center of the core.

[0013] Another object of the present invention is to provide a cooler with improved efficiency and performance.

[0014] In this specification, some elements or parameters may be indexed, such as first element and second element. In this case, unless otherwise stated, such indexing is only used to distinguish and name similar but not identical elements. The concept of priority should not be inferred from such indexing, as these terms can be interchanged without departing from the invention. Furthermore, such indexing does not imply any order of installation or use of the elements of the invention.

[0015] An embodiment of the present invention discloses a heat exchanger. The heat exchanger includes a core and a shell. The core includes multiple sets of tubular elements and multiple fluid flow channels. The multiple sets of tubular elements are in fluid communication with a first pair of inlets and outlets to define a first fluid flow therethrough. The multiple fluid flow channels receive fins therein. The multiple fluid flow channels are in fluid communication with a second pair of inlets and outlets to define a second fluid flow therethrough. The fluid flow channels sandwich at least one set of tubular elements. The shell includes a first portion and a second portion, which are assembled to form a housing and house the core therein to define an assembly configuration of the core and the shell. The shell includes multiple ribs extending from at least one of a first face and a second face toward the core housed within the shell. The rib extending from at least one of the first face and the second face includes an extending rib that, in the assembly configuration, restricts fluid flow through the core housed within the shell and the gap between the corresponding first face and the corresponding first face and the corresponding second face. At least one first fin and at least one second fin disposed at the respective first and second fluid flow channels at the ends of the core are deformed to at least partially interrupt fluid flow through the respective first and second fluid flow channels.

[0016] Specifically, in the assembly configuration, at least one extended rib interacts with and deforms at least one of the corresponding first and second fins.

[0017] Alternatively, at least one first fin and at least one second fin are deformed before assembly between the shell and the core.

[0018] Typically, the core is a metal core.

[0019] Specifically, the shell can be made of either plastic or metal.

[0020] Typically, the housing consists of a top and a bottom, which are assembled together by vibration welding, ultrasonic brazing, ultrasonic welding, and the use of threaded fasteners to form an outer shell that houses the core.

[0021] Specifically, at least one first fin and at least one second fin have the same structure and material as the other fins.

[0022] Alternatively, at least one first fin and at least one second fin may have a different construction and material than the other fins.

[0023] Typically, the extended ribs extending from the first face interact with and deform the corresponding first fin to form a seal between the top of the core and the shell, and also interrupt fluid flow through the corresponding first fluid flow channel.

[0024] Alternatively, the extending ribs extending from the second surface interact with and deform the corresponding second fins to form a seal between the bottom of the core and the shell, and also interrupt fluid flow through the corresponding second fluid flow channels.

[0025] Typically, at least one first and second fins are made of deformable material and have a configuration that, in the assembly configuration, facilitates deformation when interacting with corresponding extension ribs to prevent deformation of other elements of the core.

[0026] Furthermore, the extension rib and the corresponding at least one first fin and at least one second fin are in contact with each other, such that the force exerted by the extension rib in the assembly structure is dissipated when deforming at least one first fin and at least one second fin, and is prevented from being transmitted through at least one first fin and at least one second fin to deform other elements of the core.

[0027] In addition, the heat exchanger includes positioning elements to ensure the interaction between the extended ribs and the corresponding at least one first fin and at least one second fin in the assembly configuration.

[0028] According to one embodiment, the extended ribs are in the form of teeth.

[0029] A method for assembling a heat exchanger is also disclosed. The method includes the following steps: receiving at least a portion of a core within a housing defined by a sidewall of either the top or bottom of a shell. Subsequently, either the top or bottom of the shell in its inverted configuration, together with the core received therein, is supported within a retainer. Then, a portion of the shell, excluding the portion supported in the retainer, is aligned with the portion of the shell supported within the retainer, and the complementary and aligned portions of the shell are joined by any one of vibration welding, ultrasonic brazing, ultrasonic welding, and the use of threaded fasteners to define an assembly configuration of the shell and core, wherein, in the assembly configuration, extending ribs extend from at least one of a first and a second surface to at least one of the top and bottom of the core to form a seal between the core and the shell. Finally, during or prior to assembly, at least one of a first fin received in a first coolant flow channel of the core and a second fin received in a second coolant flow channel is deformed to interrupt fluid flow through at least one of the respective first and second fluid flow channels. Attached Figure Description

[0030] Other features, details, and advantages of the invention may be inferred from the following description of the invention. A more complete and better understanding of the invention and its many accompanying advantages will be readily obtained by referring to the following detailed description when considered in conjunction with the accompanying drawings, wherein:

[0031] Figure 1 A schematic diagram illustrating the internal details of a cooler according to an embodiment of the present invention is shown;

[0032] Figure 2a An isometric view of a cooler according to an embodiment of the present invention is shown;

[0033] Figure 2b It shows Figure 2a A top view of the cooler;

[0034] Figure 3 It shows along Figure 2b The cross-sectional view of the cooler shown by section line A-A';

[0035] Figure 4 An isometric view of the cooler is shown, without the housing used to depict the internal details of the cooler;

[0036] Figure 5a An isometric view of the first part of the housing is shown, having extending ribs constructed on its first surface;

[0037] Figure 5b An isometric view of the second portion of the housing is shown, having extending ribs constructed on its second surface; and

[0038] Figure 6 A flowchart illustrating a method for assembling a heat exchanger according to an embodiment of the present invention is shown, along with various steps involved in the method. Detailed Implementation

[0039] It should be noted that the accompanying drawings disclose the invention in sufficiently detail, and these drawings may be helpful in better defining the invention if necessary. However, the invention should not be limited to the embodiments disclosed in the specification.

[0040] In the following description and figures, the invention is described using a cooler as an example, which includes a core housed within a housing. The core includes multiple sets of tubular elements sandwiched between fluid flow channels. Specifically, a first heat exchange fluid (e.g., refrigerant) flows through the multiple sets of tubular elements to form at least a portion of a refrigerant circuit, and a second heat exchange fluid (e.g., coolant) flows through the fluid flow channels to form at least a portion of a coolant circuit. The housing includes a first portion and a second portion, wherein ribs extending upward from at least one of the first and second portions extend upward to at least one of a respective top and bottom of the core housed within the housing to prevent leakage of the second heat exchange fluid between the housing and the core. Ribs extending from at least one of the first and second portions further deform at least one of a corresponding first fin and a second fin disposed in corresponding first and second coolant flow channels at the ends of the core to at least partially interrupt fluid flow through the corresponding first and second fluid flow channels. However, the invention is also applicable to any other heat exchanger besides a cooler, where it is necessary to prevent leakage between the core and the housing, and to prevent flow through the flow channels disposed at the ends of the core, in order to achieve efficient heat exchange and improved performance of the heat exchanger.

[0041] refer to Figure 1 The diagram shows a schematic cross-sectional view depicting the internal details of a heat exchanger, particularly a cooler 100. The cooler 100 includes a core 110 housed within a housing 122. Figure 2a An isometric view of a cooler 100 according to an embodiment of the present invention is shown. Figure 2b A top view of the cooler 100 is shown. Figure 3 The cooler 100 is shown along Figure 2b The sectional view shown is a section view along section line A-A'. Figure 4 An isometric view of the cooler 100 without housing 122 is shown to depict the internal details of the cooler 100.

[0042] The core 110 includes multiple sets of tubular elements 112a, 112b sandwiched between fluid flow channels, wherein a first heat exchange fluid, particularly refrigerant, flows through the multiple sets of tubular elements 112a, 112b, and a second heat exchange fluid, particularly coolant, flows through the fluid flow channels, also known as coolant flow channels. Typically, the core 110 is made of a metallic material.

[0043] The following sections of the specification will explain the refrigerant circuit and the various components forming the refrigerant circuit. Specifically, the connections of tubular elements 112a and 112b are described, particularly the connection of inlet tubular element 112a to inlet 114a via inlet manifold 114c of manifold 114, and the connection of outlet tubular element 112b to outlet 114b via outlet manifold 114d of manifold 114. (See reference) Figure 4Since the connection between the inlet tubular element 112a and the inlet manifold 114c, the connection between the outlet tubular element 112b and the outlet manifold 114d, and the connection between the inlet 114a and the outlet 114b and the inlet manifold 114c and the outlet manifold 114d respectively are not within the scope of this invention, they will not be described in detail for the sake of brevity in this document.

[0044] Each group of tubular elements 112 is divided into an inlet tubular element 112a and a corresponding outlet tubular element 112b. More specifically, the inlet tubular element 112a and the corresponding outlet tubular element 112b are separated by a central baffle "C" extending along their length, as shown. Figure 4 As shown. An inlet tubular element 112a and a corresponding outlet tubular element 112b are directly or indirectly connected at one end via an intermediate manifold 130 to form a tubular element group. Each group of tubular elements 112a, 112b forms fluid communication between an inlet manifold 114c and an outlet manifold 114d. The inlet manifold 114c receives refrigerant from the inlet 114a and distributes the refrigerant to the inlet tubular elements 112a of the tubular element group. The refrigerant received in the inlet tubular element 112a flows there to the outlet tubular element 112b connected to the inlet tubular element 112a, and exits the outlet tubular element 112b to reach the outlet manifold 114d. During this process, the refrigerant exchanges heat with the refrigerant flowing through the adjacent refrigerant flow channel. After heat exchange with the refrigerant flowing through the adjacent refrigerant flow channel, the refrigerant collected in the outlet manifold 114d flows out through the outlet 114b.

[0045] According to embodiments of the present invention, the inlet tubular element 112a and the outlet tubular element 112b are constructed from miniature multi-port panels capable of receiving R744 as a refrigerant and withstanding high operating pressures in the range of 150 to 190 bar. This construction of the inlet tubular element 112a and the outlet tubular element 112b from miniature multi-port panels results in lighter, safer, and more compact inlet tubular elements 112a and the outlet tubular element 112b. However, the present invention is not limited to any particular construction of the inlet tubular element 112a and the outlet tubular element 112b.

[0046] In one example, inlet tubular element 112a and outlet tubular element 112b are indirectly connected to each other via intermediate manifold 130. More specifically, inlet tubular element 112a is supported between inlet manifold 114c and intermediate manifold 130, forming fluid communication between them, while outlet tubular element 112b is supported between intermediate manifold 130 and outlet manifold 114d, forming reverse fluid communication between them. This configuration of the inlet tubular element 112a and outlet tubular element 112b of each set of tubular elements forms fluid communication between inlet manifold 114c and outlet manifold 114d.

[0047] In another example, inlet tubular element 112a and outlet tubular element 112b are directly connected to each other. Specifically, inlet manifold 114c and outlet manifold 114d are connected by at least one tubular element to form a continuous fluid flow path connecting inlet manifold 114c and outlet manifold 114d. More specifically, instead of separate inlet tubular element 112a and outlet tubular element 112b connected by intermediate manifold 130 to form the connection between inlet manifold 114c and outlet manifold 114d, a plurality of continuous tubular elements form a continuous fluid flow path connecting inlet manifold 114c to outlet manifold 114d.

[0048] Similar tubular element groups construct multiple refrigerant flow paths, forming fluid communication between inlet manifold 114c and outlet manifold 114d.

[0049] The fluid flow channel, specifically the coolant flow channel, receives fins 118 therein and is in fluid communication with a second pair of inlets 120a and outlets 120b to define the flow of coolant therethrough. The coolant flow channel can be formed by a panel; however, the invention is not limited to any particular arrangement for forming the fluid flow channel. The coolant flow channel receives coolant to allow coolant flow. According to one embodiment, the coolant is a water-glycol mixture. The coolant flowing through the coolant flow channel can be the same or different coolants. The coolant flow channel 116 clamps at least one set of tubular elements 112a, 112b in between.

[0050] With this configuration, each of the first coolant flow channels 116a and 116b located at the ends of the core 110 contacts a set of tubular elements 112a, 112b only on one side. Therefore, the coolant flowing through each of the first and second coolant flow channels 116a and 116b undergoes heat exchange only from one side, resulting in inefficient heat exchange. However, in the case of the centrally located coolant flow channels 116, excluding the first and second coolant flow channels 116a and 116b located at the ends of the core 110, each centrally located coolant flow channel 116 contacts two sets of tubular elements 112a, 112b, one on each side. Therefore, the coolant flowing through each centrally located coolant flow channel 116 exchanges heat with the refrigerant flowing through two adjacent sets of tubular elements 112a, 112b, each set of tubular elements 112a, 112b located on opposite sides and forming part of a refrigerant circuit. Specifically, the coolant flowing through each centrally located coolant flow channel 116 undergoes heat exchange from both sides, and this heat exchange is effective. Furthermore, the efficiency and performance of the cooler are reduced due to coolant leakage between the housing 122 and the core 110, particularly between the top and bottom of the housing and core 110. Moreover, experimental data show that more coolant flows through the first and second coolant flow channels 116a and 116b compared to the centrally located coolant flow channels.

[0051] Considering the above, in order to improve the efficiency and performance of the cooler 100, it is necessary to prevent coolant leakage between the housing 122 and the core 110, especially at the top and bottom of the core 110. To further improve the efficiency and performance of the cooler 100, more coolant needs to flow through the centrally located coolant flow channel 116, rather than the first and second coolant flow channels 116a and 116b located at the ends of the core 110.

[0052] The housing 122 includes a first portion 122a and a second portion 122b, which are assembled to form an outer shell for receiving the core 110 therein, thereby defining the assembly configuration of the core 110 and the housing 122. However, the invention is not limited to any particular configuration of the housing 112, as long as the housing 122 is formed of a plurality of components that can be assembled together to form an outer shell in which the core 110 is housed. Typically, the housing 122 is made of a plastic material. Alternatively, the housing 122 may be metallic. At least one of the first portion 122a and the second portion 122b, particularly at least one of the first surface 122c of the first portion 122a and the second surface 122d of the second portion 122b, includes a rib 124 extending therefrom and toward the core 110 housed in the housing 122. The ribs 124 extending from the first surface 122c and the second surface 122d include first and second extending ribs 124a and 124b, respectively, which are referred to as extending ribs 124a and 124b, respectively, extending to the top and bottom of the core 110 housed within the housing 122. Figure 5a A first extending rib 124a is shown extending from the first surface 122c of the first portion 122a of the housing 122. Similarly, Figure 5b A second extending rib 124b is shown extending from the second surface 122d of the second portion 122b of the housing 122. The first and second extending ribs 124a and 124b extend vertically from the first surface 122c of the first portion 122a and the second surface 122d of the second portion 122b, respectively. More specifically, the first extending rib 124a and the second extending rib 124b extend upward to the respective top and bottom of the core 110 housed within the outer shell formed by assembling the first and second portions 122a and the housing 122b of the housing 122. Furthermore, the first extending rib 124a extends along the width of the first portion 122a, and the second extending rib 124b extends along the width of the second portion 122b. Typically, the ribs 124 including the first extending rib 124a and the second extending rib 124b are integrally formed on the respective first surface 112c and second surface 122d of the housing 122 during the molding of the housing 122 itself. Thus, no special process is required to form the ribs 124, including the extending ribs 124a and 124b on the corresponding first surface 122c and second surface 122d. According to an embodiment of the invention, the first extending rib 124a and the second extending rib 124b are toothed. However, the invention is not limited to the specific construction of the first extending rib 124a and the second extending rib 124b, as long as the first extending rib 124a and the second extending rib 124b can extend to at least one first fin 118a and at least one second fin 118b respectively and interact with and deform them to prevent leakage between the core 110 and the shell 122 and to interrupt the flow through the first coolant flow channel 116a and the second coolant flow channel respectively.

[0053] Preferably, the first portion 122a of the housing 122 is the top, and the second portion 122b of the housing 122 is the bottom. The first portion 122a and the second portion 122b are joined together by vibration welding, ultrasonic brazing, ultrasonic welding, and the use of threaded fasteners to form a shell that houses the core 110 therein and defines the assembly configuration of the housing 122 relative to the core 110. However, the invention is not limited to any particular method for forming a joint between the first portion 122a and the second portion 122b of the housing 122 to define the assembly configuration of the housing 122 relative to the core 110.

[0054] In the assembly configuration of the housing 122 relative to the core 110, at least one of the first and second extending ribs 124a and 124b extends from at least one of the first surface 122c and the second surface 122d to at least one of the respective top and bottom surfaces of the core 110. Therefore, in the assembly configuration of the housing 122 relative to the core 110, at least one of the first and second extending ribs 124a and 124b restricts fluid flow through the gap between at least one of the respective first surface 122c and the second surface 122d of the housing 122 and the core 110 housed within the housing 122.

[0055] In one embodiment, the extension rib 124a is formed only on the first surface 122 and extends from the first surface 122c to the top of the core 110 to restrict fluid flow through the gap between the first surface 122c and the top of the core 110. In another embodiment, the extension rib 124b is formed only on the second surface 122d and extends upward from the second surface 122d to the bottom of the core 110 to restrict fluid flow through the gap between the second surface 122d and the bottom of the core 110. According to yet another embodiment of the invention, the extension rib 124a is formed on the first surface 122c, and the extension rib 124b is formed on the second surface 122d. The extension rib 124a extends upward from the first surface 122c to the top of the core 110 to restrict fluid flow through the gap between the first surface 122c and the top of the core 110. Similarly, the extension rib 124b extends upward from the second face 122d to the bottom of the core 110 to restrict fluid flow through the gap between the second face 122d and the bottom of the core 110. The extension ribs 124a and 124b prevent leakage of the second heat exchange fluid, particularly the coolant between the housing 122 and the core 110.

[0056] A first coolant flow channel 116a and a second coolant flow channel 116b, located at the ends of the core 110, respectively receive at least one first fin 118a and at least one second fin 118b. More specifically, the first coolant flow channel 116a receives one or more first fins 118a. Similarly, the second coolant flow channel 116b receives one or more second fins 118b. A centrally located coolant flow channel 116 receives at least one fin 118. At least one first fin 118a and at least one second fin 118b are deformable to restrict coolant flow through the respective first coolant flow channel 116a and second coolant flow channel 116b. According to an embodiment of the invention, at least one first fin 118a and at least one second fin 118b have the same construction and material as the other fins 118 housed in the centrally located coolant flow channel 116. According to another embodiment of the invention, at least one first fin 118a and at least one second fin 118b have a different construction and material from the other fins 118 housed in the centrally located coolant flow channel 116. However, the invention is not limited to whether the first and second fins 118a and 118b have the same material and construction as the other fins 118 housed in the centrally located coolant flow channel 116a and 116b, as long as the first and second fins 118a and 118b are deformable to interrupt flow through the corresponding first and second coolant flow channels 116a and 116b.

[0057] According to embodiments of the invention, at least one first fin 118a and at least one second fin 118b are deformed before assembly between the housing 122 and the core 110. At least one first fin 118a and at least one second fin 118b can be deformed using any method such as hammering, stamping, and forming. However, the invention is not limited to any particular method used to deform at least one first fin 118a and at least one second fin 118b.

[0058] Alternatively, at least one of the first and second extension ribs 124a and 124b interacts with and deforms at least one of the corresponding first fins 118a and second fins 118b disposed in the respective first coolant flow channel 116a and second fluid flow channel 116b at the end of the core 110. More specifically, the plurality of extension ribs 124a and 124b deform at least one first fin 118a and at least one second fin 118b, respectively, to at least partially interrupt fluid flow through the first coolant flow channel 116a and the second fluid flow channel 116b, respectively. In one embodiment, the extension rib 124a interacts with and deforms at least one first fin 118a disposed in the first coolant flow channel 116a to interrupt coolant flow through the first coolant flow channel 116a. In another embodiment, the extension rib 124b interacts with and deforms at least one second fin 118b disposed in the second coolant flow channel 116b to interrupt coolant flow through the second coolant flow channel 116b. According to another embodiment of the invention, the extending rib 124a interacts with and deforms at least one first fin 118a, and the extending rib 124b interacts with and deforms at least one second fin 118b. The deformation of at least one first fin 118a and at least one second fin 118b at least partially interrupts the flow through the corresponding first coolant flow channel 116a and second fluid flow channel 116b, thereby promoting flow through the centrally located flow channel 116 and improving the efficiency and performance of the cooler 100. At least one first fin 118a and at least one second fin 118b may be deformed before or during assembly between the core 110 and the housing 122. More specifically, any of the vibration welding, ultrasonic brazing, or ultrasonic welding used to form a joint between the first portion 122a and the second portion 122b results in the extension ribs 124a and 124b interacting with the corresponding first and second fins 118a and 118b, wherein the interaction between the extension ribs 124a and 124b and the corresponding first and second fins 118a and 118b causes deformation of the first and second fins 118a and 118b. However, the invention is not limited to whether the deformation of the fins 118a and 118b occurs before or during assembly, as long as the deformation of the first and second fins 118a and 118b interrupts the flow through the corresponding first and second coolant flow channels 116a and 116b. The cooler 100 also includes positioning elements to ensure that the extension ribs 124a and 124b and the corresponding fins 118a and 118b are aligned relative to each other and interact with each other during assembly between the housing 122 and the core 110 so that the extension ribs 124a and 124b deform the corresponding fins 118a and 118b.

[0059] More specifically, the extending rib 124a extending from the first surface 122c interacts with and deforms the corresponding first fin 118a, thereby forming a seal not only between the first surface 122c of the housing 122 and the top of the core 110, but also interrupting fluid flow through the corresponding first fluid flow channel 116a. Similarly, the extending rib 124b extending from the second surface 122d interacts with and deforms the corresponding second fin 118b, thereby forming a seal not only between the second surface 122d of the housing 122 and the bottom of the core 110, but also interrupting fluid flow through the corresponding second fluid flow channel 116b. At least one first fin 118a and at least one second fin 118b are made of a deformable material and are configured such that, in the assembled configuration, their interaction with the corresponding extending ribs 124a and 124b facilitates their deformation to prevent deformation of other elements of the core 110. The extension ribs 124a and 124b, and the corresponding first and second fins 118a and 118b, are in contact with each other such that the forces exerted by the extension ribs 124a and 124b during assembly between the core 110 and the housing 122 are dispersed when the corresponding first and second fins 118a and 118b are deformed. Therefore, the forces exerted by the extension ribs 124a and 124b are prevented from being transmitted to other elements of the core 110 and deforming them. The structure / thickness of the first and second fins 118a and 118b causes them to deform when subjected to the deformation forces of the corresponding extension ribs 124a and 124b. More specifically, the forces exerted by the extension ribs 124a and 124b deform only the first and second fins 118a and 118b, without deforming other elements of the core 110, such as the subsequent tubular elements 112a and 112b, and the fins 118 housed in the centrally located coolant flow channel 116.

[0060] A method 400 for assembling a heat exchanger is also disclosed, particularly a cooler 100 according to an embodiment of the invention. Figure 6A block diagram illustrating the steps of a method 400 for assembling a cooler 100 is shown. Specifically, method 400 includes the step of receiving a core 110 within either of complementary portions 122a and 122b of a housing 122. Subsequently, either of the complementary portions 122a and 122b, together with the core 110 received therein, is supported within a retainer 300. Subsequently, the complementary portions 122a and 122b are aligned and joined to form an assembly configuration of the core 110 and the housing 122. In the assembly configuration, extending ribs 124a and 124b extend from a first surface 122c and a second surface 122d to the core 110 to form a seal between the core 110 and the housing 122. Furthermore, in the assembly configuration, at least one of the extending ribs 124a and 124b deforms at least one of a corresponding first fin 118a received in a first coolant flow channel 116a and a corresponding second fin 118a received in a second coolant flow channel 116b. The deformation of at least one of the first fin 118a and the second fin 118b interrupts the flow through at least one of the corresponding first coolant flow channels 116a and the second coolant flow channels 116b. Although the various steps of method 400 are depicted by boxes in the flowchart, any number of steps described as method boxes can be combined in any order or performed in parallel to employ method 400 or alternative methods. Furthermore, individual blocks can be removed from the flowchart describing the method without departing from the scope and limits of the invention. Refer to the following description and... Figure 6 Method 400 can be understood.

[0061] Method 400 includes step 402, receiving at least a portion of the core 110 within a housing defined by a sidewall of either the top 122a or the bottom 122b of the housing 122. Thereafter, the method includes step 404, supporting either the top 122a or the bottom 122b of the housing 122 in its inverted configuration, together with the core 110 housed therein, within a retainer 300. Subsequently, the method includes step 406: aligning a portion of the housing 122, excluding the portion supported in the retainer 300, with the portion of the housing 122 supported within the retainer 300, and joining the complementary and aligned portions 122a and 122b of the housing 122 by vibration welding, ultrasonic brazing, ultrasonic welding, and the use of threaded fasteners to define an assembly configuration of the housing 122 and the core 110. According to an embodiment of the invention, complementary alignment portions 122a and 122b of the housing 122 are pushed towards each other by a synotrode and subjected to vibration in a frequency range of 20 kHz to form a connection between portions 122a and 122b of the housing 122. In the assembly configuration, at least one of the extending ribs 124a and 124b extends from at least one of the first surface 122c and the second surface 122d to at least one of the top and bottom of the core 110 to form a seal between the core 110 and the housing 122. Finally, the method includes step 408, during and prior to assembly, deforming at least one of the first fins 118a housed in the first coolant flow channel 116a of the core 110 and the second fins 118b housed in the second coolant flow channel 116b to interrupt fluid flow through at least one of the corresponding first coolant flow channel 116a and second coolant flow channel 116b.

[0062] Those skilled in the art can make modifications and improvements to the heat exchanger, particularly the cooler, as described above, and such modifications and improvements will still be considered within the scope of the invention, provided that the heat exchanger comprises a core and a shell. The core comprises multiple sets of tubular elements and multiple fluid flow channels. The multiple sets of tubular elements are in fluid communication with a first pair of inlets and outlets to define a first fluid flow therethrough. The multiple fluid flow channels receive fins therein. The multiple fluid flow channels are in fluid communication with a second pair of inlets and outlets to define a second fluid flow therethrough. The fluid flow channels sandwich at least one set of tubular elements in between. The shell comprises a first portion and a second portion, which are assembled to form a housing and house the core therein to define an assembly configuration of the core and the housing. The shell includes multiple ribs extending from at least one of the first and second faces of the shell toward the core housed within the shell. Ribs extending from at least one of the first and second faces include extending ribs that, in the assembly configuration, restrict fluid flow through the gap between the core housed within the shell and at least one of the corresponding first and second faces. At least one first fin and at least one second fin disposed in the corresponding first and second fluid flow channels at the end of the core are deformed to at least partially interrupt the flow of fluid through the corresponding first and second fluid flow channels.

[0063] Obviously, many modifications and variations of the present invention are possible based on the above teachings. Therefore, it should be understood that the present invention may be practiced in ways other than those specifically described herein.

[0064] In no event should the invention be limited to the embodiments specifically described herein, as other embodiments may exist. The invention is extended to any equivalent apparatus and any technically operational combination of apparatus.

Claims

1. A heat exchanger (100), comprising: a core (110), comprising: a plurality of sets of tubular elements (112a, 112b) in fluid communication with a first pair of inlet (114a) and outlet (114b) ports to define a first fluid flow therethrough; a plurality of fluid flow channels (116) containing fins (118) therein in fluid communication with a second pair of inlet (120a) and outlet (120b) ports to define a second fluid flow therethrough, the fluid flow channels (116) being adapted to sandwich at least one set of tubular elements (112a, 112b) therebetween; a shell (122) comprising a first portion (122a) and a second portion (122b) adapted to be assembled to form an enclosure and to receive the core (110) therein to define an assembled configuration of the core (110) and the shell (122), the shell (122) comprising a plurality of ribs (124) adapted to extend from at least one of a first face (122c) and a second face (122d) of the shell (122) towards the core (110) received therein, characterized in that the ribs (124) extending from at least one of the first face (122c) and the second face (122d) comprise extended ribs (124a, 124b) adapted to restrict, in the assembled configuration, a fluid flow through a gap between the core (110) received in the shell (122) and at least one of the corresponding first face (122c) and the second face (122d), at least one first fin (118a) and at least one second fin (118b) disposed in at least one of the corresponding first and second fluid flow channels (116a, 116b) at an end of the core (110) being adapted to deform to at least partially interrupt the fluid flow through the corresponding first and second fluid flow channels (116a, 116b).

2. The heat exchanger (100) according to the preceding claim, wherein at least one of the extended ribs (124a, 124b) is adapted to interact with and deform at least one of the corresponding first fin (118a) and the second fin (118b) in the assembled configuration to interrupt the fluid flow through the first and second fluid flow channels (116a, 116b), respectively.

3. The heat exchanger (100) of any one of the preceding claims, wherein, the at least one first fin (118a) and the at least one second fin (118b) are deformed prior to being assembled between the shell (122) and the core (110).

4. The heat exchanger (100) according to claim 1 or 2, wherein the core (110) is a metallic core.

5. The heat exchanger (100) according to claim 1 or 2, wherein the shell (122) is of any one of a plastic material or a metal.

6. The heat exchanger (100) according to claim 1 or 2, wherein the shell (122) comprises a top portion (122a) and a bottom portion (122b) assembled together by any one of a vibration welding, an ultrasonic brazing, an ultrasonic welding and the use of threaded fasteners to form an enclosure in which the core (110) is received.

7. The heat exchanger (100) according to claim 1 or 2, wherein the at least one first fin (118a) and the at least one second fin (118b) have the same configuration and material as the other fins (118).

8. The heat exchanger (100) according to claim 1 or 2, wherein the at least one first fin (118a) and the at least one second fin (118b) have a different configuration and material than the other fins (118).

9. The heat exchanger (100) according to claim 1 or 2, wherein The extension rib (124a) extending from the first face (122c) is adapted to interact with and deform the corresponding at least one first fin (118a) to form a seal between the top of the core (110) and the shell (122) and also to interrupt the flow of fluid through the corresponding first fluid flow channel (116a).

10. The heat exchanger (100) according to claim 1 or 2, wherein The extension rib (124b) extending from the second face (122d) is adapted to interact with and deform the corresponding at least one second fin (118b) to form a seal between the bottom of the core (110) and the shell (122) and also to interrupt the flow of fluid through the corresponding second fluid flow channel (116b).

11. The heat exchanger (100) according to claim 1 or 2, wherein The at least one first and second fin (118a, 118b) is made of a deformable material and has a configuration which, in the assembled configuration, facilitates its deformation when interacting with the corresponding extension rib (124a, 124b) to prevent deformation of other elements of the core (110).

12. The heat exchanger (100) according to claim 1 or 2, wherein The extension rib (124a, 124b) and the corresponding at least one first fin (118a) and at least one second fin (118b) are adapted to come into contact with each other so that the force exerted by the extension rib (124a, 124b) in the assembled configuration is dissipated in deforming the at least one first fin (118a) and the at least one second fin (118b) and is prevented from being transmitted through the at least one first fin (118a) and the at least one second fin (118b) to deform other elements of the core (110).

13. The heat exchanger (100) of claim 1 or 2, comprising positioning elements to ensure the interaction between the extension rib (124a, 124b) and the corresponding at least one first and second fin (118a, 118b) in the assembled configuration.

14. The heat exchanger (100) as claimed in claim 1 or 2, wherein, The extension rib (124a, 124b) is toothed.

15. A method for assembling a heat exchanger (100), the method comprising the steps of: receiving at least a portion of the core (110) within an outer casing defined by a side wall of either of the top (122a) and the bottom (122b) of the shell (122); supporting either of the top (122a) and the bottom (122b) of the shell (122) in its inverted configuration, together with the core (110) housed therein, within a holder (300); aligning the portion of the shell (122) other than the portion supported within the retainer (300) with the portion of the shell (122) supported within the retainer (300), and joining the complementary and aligned portions of the shell (122) by any of vibration welding, ultrasonic brazing, ultrasonic welding, and use of threaded fasteners to define an assembled configuration of the shell (122) and the core (110), wherein, in the assembled configuration, the extending ribs (124a, 124b) extend from at least one of the first face (122c) and the second face (122d) to at least one of the top and the bottom of the core (110) to form a seal between the core (110) and the shell (122); and deforming at least one of the first fin (118a) contained in the first coolant flow passage (116a) of the core (110) and the second fin (118b) contained in the second coolant flow passage (116b) during or prior to assembly to interrupt fluid flow through at least one of the respective first coolant flow passage (116a) and the second fluid flow passage (116b). deforming at least one of the first fin (118a) contained in the first coolant flow passage (116a) of the core (110) and the second fin (118b) contained in the second coolant flow passage (116b) during or prior to assembly to interrupt fluid flow through at least one of the respective first coolant flow passage (116a) and the second fluid flow passage (116b).

Images