Tubular element for heat exchanger

Abstract

A tubular element for a heat exchanger includes at least one set of inlet channels, at least one set of outlet channels, and at least one separating wall disposed between the at least one set of inlet channels and the at least one set of outlet channels. The at least one set of inlet channels and the at least one set of outlet channels are asymmetrically configured with respect to the at least one separation wall.

Description

Technical Field

[0001] The present invention relates to a heat exchanger for cooling a battery in an electric and / or hybrid vehicle. More specifically, the present invention relates to an improved tubular element of a heat exchanger for cooling battery cells. Background Art

[0002] Thermal management systems are crucial for the efficient operation of battery packs in vehicles such as electric vehicles and hybrid electric vehicles. The battery pack is the energy source of such vehicles and supplies the required electric power to the traction motor and other electrical and / or electronic components. The battery pack includes a plurality of rechargeable battery cells and has a narrow operating temperature range, so the battery pack must be maintained within the specified operating temperature range to operate effectively. Under high temperature conditions and / or vehicle operating conditions, the battery pack needs to be cooled to keep the temperature within the specified operating temperature range, while under low temperature conditions, the battery pack needs to be heated to reach the optimal temperature. Deviation of the battery pack temperature from the specified temperature range affects the battery pack performance, reducing battery efficiency and durability. Sometimes, due to the deviation of the battery pack temperature from the specified temperature range, the battery may be permanently damaged or destroyed, and overheating of the battery cells can even cause fires and other safety-related problems.

[0003] Typical thermal management systems for cooling and heating battery packs rely on many subsystems such as coolers, air-fluid heat exchangers, electric heaters, etc. The cooler or air-fluid heat exchanger is adapted to cool a heat exchange fluid in a battery circuit, such as a refrigerant or coolant, to cool the battery pack, while the electric heater is adapted to heat the heat exchange fluid in the battery circuit to increase the temperature of the battery pack.

[0004] Generally, traditional heat exchangers include a plurality of heat cooling tube arrangements for cooling the battery cells of a battery pack. Such heat cooling tube arrangements include heat cooling tubes having two sets of channels / microchannels, including an inlet channel and an outlet channel through which a fluid / coolant flows, and a central channel configured between the two sets of channels and blocked at two opposite ends, an inlet / outlet tank at one end of the cooling tube, and a return tank / return header at the other end of the cooling tube to allow the fluid to pass through the outlet channel and flow along a U-shaped flow path. The heat cooling tube arrangement is adapted to cool the battery cells that are indirectly in contact with the fluid / coolant flowing through the two sets of channels / microchannels and along the U-shaped flow path.

[0005] However, in existing cooling tubes, during the operation of the heat exchanger, it is possible for perforations / cracks to appear on the walls of the central channel. Due to the perforations / cracks on the walls of the central channel, coolant leakage may occur between the inlet channel and the outlet channel through the central channel, which will reduce the cooling efficiency of the heat exchanger. In addition, through the cracks / perforations on the central channel wall, the accumulation of fluid and / or coolant in the central channel changes, which can lead to corrosion of the central channel wall, resulting in the failure of the cooling tube.

[0006] Therefore, there is a need for a simple and robust thermal cooling tube that can overcome the above disadvantages of traditional cooling tubes. In addition, there is a need for a simple and cost-effective tank and tube assembly for U-shaped flow cooling of battery cells in a battery pack. Summary of the Invention

[0007] The present invention discloses a tubular element (hereinafter also referred to as a cooling tube) for a heat exchanger, which is provided with one or more thick partition walls between multiple groups of inlet and outlet channels, thus eliminating the disadvantages of traditional cooling tubes. In addition, one or more thick partition walls between multiple groups of inlet and outlet channels prevent the leakage of coolant / fluid between the inlet and outlet channels, and avoid the opportunity of corrosion of the tubular element by preventing the accumulation of fluid. In addition, multiple groups of inlet and outlet channels of the disclosed tubular element provide two or more U-shaped flow channels passing through the cooling tube, thereby improving the performance of the thermal cooling tube assembly or the heat exchanger.

[0008] According to an embodiment of the present invention, the disclosed tubular element includes at least one group of inlet channels, at least one group of outlet channels, and at least one partition wall, which is configured between at least one group of inlet channels and at least one group of outlet channels. At least one group of inlet channels and at least one group of outlet channels are configured asymmetrically with respect to at least one partition wall.

[0009] Adjacent inlet channels of at least one group of inlet channels are arranged in series and are separated from each other by a first partition wall in each case. In addition, the thickness of the first partition wall is less than the thickness of at least one partition wall. In addition, the thickness of the partition wall can be greater than or equal to the gap between adjacent first partition walls.

[0010] Adjacent outlet channels of at least one group of outlet channels are arranged in series and are separated from each other by a second partition wall in each case. The thickness of the second partition wall is less than the thickness of at least one partition wall. In addition, the thickness of the partition wall is greater than or equal to the gap between adjacent second partition walls.

[0011] The cross-sectional areas of at least two individual inlet channels within at least one group of inlet channels can be different from each other.

[0012] The cross-sectional areas of at least two individual outlet channels within at least one group of outlet channels can be different from each other.

[0013] The cumulative cross-sectional area of at least one set of inlet channels can be different from the cumulative cross-sectional area of at least one set of outlet channels.

[0014] In addition, the number of inlet channels in at least one set of inlet channels is different from the number of outlet channels in at least one set of outlet channels. In one embodiment, the ratio of the number of inlet channels in at least one set of inlet channels to the number of outlet channels in at least one set of outlet channels can be in the range of 1.5 to 3.

[0015] In another embodiment, the ratio of the number of outlet channels in at least one set of outlet channels to the number of inlet channels in at least one set of inlet channels is in the range of 1.5 to 3.

[0016] In one embodiment, the tubular element can have a flat profile extending along an extension axis parallel to the general direction of the inlet and outlet channels. In addition, at least a portion of the flat profile can be wavy along the extension axis.

[0017] According to another embodiment, the present invention discloses a tank and tube assembly for a heat exchanger. The tank and tube assembly includes a tubular element, such as the tubular element disclosed above, and a fluid distribution tank coupled to a first end of the tubular element. The tubular element includes at least one set of inlet channels; at least one set of outlet channels configured to be in fluid communication with at least one set of inlet channels to form at least one U-shaped flow path for fluid through the tubular element; and at least one separation wall configured between at least one set of inlet channels and at least one set of outlet channels. At least one set of inlet channels and at least one set of outlet channels are configured asymmetrically with respect to at least one separation wall. The fluid distribution tank includes at least one inlet opening fluidly connected to at least one set of inlet channels, and at least one outlet opening fluidly connected to at least one set of outlet channels.

[0018] In this specification, some elements or parameters may be indexed, such as a first element and a second element. In such a case, unless otherwise specified, such indexing is only used to distinguish and name similar but different elements. The concept of priority should not be inferred from such indexing, as these terms can be interchanged without departing from the present invention. In addition, such indexing does not imply any order of installation or use of the elements of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other features, details, and advantages of the present invention can be inferred from the following description of the present invention. When considered in conjunction with the drawings, a more complete understanding of the present invention and its many attendant advantages will be readily obtained and better understood by reference to the following detailed description, in which:

[0020] Figure 1Shows a tank and tube assembly with a single U-shaped flow path for a heat exchanger according to an embodiment of the present invention;

[0021] Figure 2 Shows Figure 1 the tubular element of the tank and tube assembly having a set of inlet channels and a set of outlet channels;

[0022] Figure 3 Shows a tank and tube assembly with two U-shaped flow paths according to an embodiment of the present invention;

[0023] Figure 4 Shows Figure 3 the tubular element of the tank and tube assembly having a set of inlet channels and two sets of outlet channels;

[0024] Figure 5 Shows a tank and tube assembly with a fluid distribution tank according to an embodiment of the present invention, the fluid distribution tank having an inlet and an outlet for two U-shaped flow paths;

[0025] Figure 6 Shows Figure 5 the tubular element of the tank and tube assembly having two sets of inlet channels and a set of outlet channels;

[0026] Figure 7 Shows a tank and tube assembly with a fluid distribution tank according to an embodiment of the present invention, the fluid distribution tank having an inlet and two outlets;

[0027] Figure 8 Shows Figure 7 the tubular element of the tank and tube assembly having a set of inlet channels and two sets of outlet channels;

[0028] Figure 9 Shows a tank and tube assembly with a return tank according to an embodiment of the present invention, the return tank having a fluid guiding wall;

[0029] Figure 10 Shows a tank and tube assembly with a fluid distribution tank according to an embodiment of the present invention, the fluid distribution tank having two inlets and an outlet; and

[0030] Figure 11 Shows Figure 10 the tubular element of the tank and tube assembly having two sets of inlet channels and a set of outlet channels. Detailed Description

[0031] It must be noted that the drawings disclose the present invention in sufficient detail and, if necessary, the drawings assist in better defining the present invention. However, the present invention should not be limited to the embodiments disclosed in the specification.

[0032] In the following description and drawings, the present invention is explained by way of examples of tubular elements for heat exchangers and tank and tube assemblies, where each tank and tube assembly is formed by assembling a tubular element and one or more end tanks mounted to opposite ends of the tubular element to create one or more U-shaped flow channels for a heat exchange fluid for cooling battery cells of an electric and / or hybrid vehicle. Additionally, the disclosed tank and tube assemblies can be easily retrofitted with battery cells in a battery pack, which results in optimal space utilization, i.e., an effective cooling tank and tube assembly density between the battery cells, with space gaps above and below the battery module.

[0033] It should be understood that the concepts of the present invention are applicable to any other applications in vehicle and non-vehicle environments where a cooling tube arrangement is required to cool battery cells, and all such applications are within the scope of the present invention without any limitation.

[0034] Reference Figure 2 、 4 、6, 8, and 11, the present invention discloses a tubular element 102 for a heat exchanger, which includes at least one set of inlet channels 104a, 104b, at least one set of outlet channels 106a, 106b, and at least one separating wall 108a, 108b, which is configured between the at least one set of inlet channels 104a, 104b and the at least one set of outlet channels 106a, 106b. The at least one set of inlet channels 104a, 104b and the at least one set of outlet channels 106a, 106b are configured asymmetrically with respect to the at least one separating wall 108a, 108b. For example, the inlet channels 104a, 104b and the outlet channels 106a, 106b can be formed by an extrusion process, and the separating walls 108a, 108b can be non-extruded components.

[0035] Referring to Figure 1 、 3, 5, 7, 9, and 10, the present invention discloses a tank and tube assembly 150 of a heat exchanger for cooling battery cells of a battery pack. For example, the battery pack can be installed in an electric or hybrid vehicle, wherein the battery cells of the battery pack can be rechargeable cylindrical cells. The tank and tube assembly 150 includes a fluid distribution tank 152 coupled to a first end 103a of a tubular element 102 and a return tank 180 coupled to a second end 103b of the tubular element 102. The first end 103a and the second end 103b are laterally open ends of the tubular element 102, wherein the second end 103b is opposite to the first end 103a. The first end 103a of the tubular element 102 can be an inlet / outlet end of the tubular element 102 through which fluid enters and exits the tubular element 102. The second end 103b can be a return end of the tubular element 102, wherein the return tank 180 causes the fluid leaving the tubular element 102 to return / diverge to flow through the tubular element 102 along a U-shaped flow path. For example, all components of the tank and tube assembly 150 can be coupled to each other by a suitable connection process, such as but not limited to a brazing process.

[0036] The fluid distribution tank 152 includes a first plate 158 and a second plate 160 coupled to the first plate 158 to define a distribution chamber having a connection opening 164 therebetween. For example, the first plate and the second plate can be coupled by a brazing process. The connection opening 164 is adapted to form a connection between the fluid distribution tank 152 and the tubular element 102. The connection opening 164 of the fluid distribution tank 152 is adapted to receive and securely hold the first end 103a of the tubular element 102. In addition, at least one of the first plate 158 and the second plate 160 is provided with at least one inlet opening 154a, 154b for the entry of fluid relative to the distribution chamber, and at least one of the first plate 158 and the second plate 160 is provided with at least one outlet opening 156a, 156b for the exit of fluid relative to the distribution chamber. In addition, at least one dividing wall 166a, 166b can be provided between the first plate 158 and the second plate 160 to divide the distribution chamber into at least two sub-chambers, such as sub-chambers 162a, 162b, and 162c. For example, at least one of the first plate 158 and the second plate 160 can be a stamped metal plate. In addition, at least one dividing wall 166a, 166b can be a rib extending from at least one of the first plate 158 and the second plate 160.

[0037] In addition, the first plate 158 and the second plate 160 can have side edges 168 on two or more sides, such as three sides. The side edges 168 of the first plate 158 and the second plate 160 project towards each other. The side edges 168 of the first plate 158 and the second plate 160 can be joined to each other. In addition, the adjacent side edges 168 of the first plate 158 and the second plate 160 can be crimped to each other.

[0038] In addition, the return tank 180 includes a third plate 182 and a fourth plate 184 coupled to the third plate 182 to define a return chamber (not shown) having an orifice 186, thereby forming a connection between the return tank 180 and the tubular element 102. For example, the third plate 182 and the fourth plate 184 may be coupled by a brazing process. The orifice 186 of the return tank 180 is adapted to receive and securely hold the second / return end 103b of the tubular element 102. In addition, the return chamber of the return tank 180 and the inlet and outlet channels 104a, 104b, 106a, 106b of the tubular element 102 are in fluid communication through the orifice 186 such that fluid flowing through the inlet channels 104a, 104b is collected in the return chamber and further fluid is directed / supplied to the outlet channels 106a, 106b to flow along a U-shaped flow path in the tubular element 102. In one embodiment, the cross-section of the return tank 180 may have a rectangular shape. In another embodiment, the cross-section of the return tank 180 may have a generally U-shape.

[0039] In addition, each of the third plate 182 and the fourth plate 184 may have side edges 190 on two or more sides, such as three sides. The side edges 190 of the third plate 182 and the fourth plate 184 project towards each other and may be joined to each other. For example, the adjacent side edges 190 of the third plate 182 and the fourth plate 184 may be crimped to each other.

[0040] In one embodiment, as Figure 1 shown, the fluid distribution tank 152 may include a dividing wall 166a located between a first plate 158 and a second plate 160 to divide the distribution chamber into two sub-chambers 162a and 162b. The two sub-chambers 162a and 162b extend from a connection opening 164. For example, the cross-sections of the two sub-chambers 162a and 162b may have a rectangular shape and the dividing wall 166a may be straight. In addition, the dividing wall 166a may project from at least one of the first plate 158 and the second plate 160. For example, the dividing wall 166a may project from the first plate 158 and be formed by a stamping process. The dividing wall 166a may be coupled to the second plate 160 by a joining process such as a brazing process. In addition, an inlet opening 154a and an outlet opening 156a may be provided on the first plate 158, wherein the inlet opening 154a may be in fluid communication with the sub-chamber 162a for fluid entry relative to the sub-chamber 162a and the outlet opening 156a may be in fluid communication with the sub-chamber 162b for fluid exit relative to the sub-chamber 162b. In addition, the volumes of the respective sub-chambers 162a and 162b are different from each other. For example, the volume of the sub-chamber 162a may be greater than the volume of the sub-chamber 162b.

[0041] In one embodiment, as Figure 2As shown, the tubular element 102 may include a set of inlet channels, such as inlet channels 104a-1, 104a-2... 104a-N (hereinafter, also collectively referred to as inlet channels 104a), and a set of outlet channels, such as outlet channels 106a-1, 106a-2... 106a-N (hereinafter, collectively referred to as outlet channels 106a). The set of inlet channels 104a and the set of outlet channels 106a are separated by a separating wall 108a. The separating wall may be configured to be close to the longitudinal sidewall of the tubular element 102 and close to the outlet channels 106a. In addition, adjacent inlet channels, such as inlet channels 104a-1 and 104a-2, are arranged in series and are separated from each other by a first dividing wall 110 in each case. The thickness of the first dividing wall 110 is less than the thickness of the separating wall 108a. Similarly, adjacent outlet channels, such as outlet channels 106a-1 and 106a-2, are arranged in series and are separated from each other by a second dividing wall 112. The thickness of the second dividing wall 112 is less than the thickness of the separating wall 108a. For example, the thickness of the separating wall 108a may be greater than or equal to the gap between adjacent first dividing walls 110 or the gap between adjacent second dividing walls 112.

[0042] In addition, the cross-sectional areas of at least two individual inlet channels (such as channels 104a-1 and 104a-N) within the set of inlet channels 104a may be different from each other. In addition, the cross-sectional areas of at least two individual outlet channels (such as outlet channels 106a-1 and 106a-2) within the set of outlet channels 106a may be different from each other. In addition, the cumulative cross-sectional area of the set of inlet channels 104a may be different from the cumulative cross-sectional area of the set of outlet channels 106a. In addition, the number of inlet channels within the set of inlet channels 104a may be different from the number of outlet channels within the set of outlet channels 106a. The ratio of the number of inlet channels within the set of inlet channels 104a to the number of outlet channels within the set of outlet channels 106a may be in the range of 1.5 to 3.

[0043] In addition, the outlet channels 106a are configured to be in fluid communication with the inlet channels 104a at the second end 103b through a return tank 180 to form a U-shaped flow path for the fluid through the tubular element 102. The inlet channels 104a are fluidly connected to the sub-chamber 162a such that the fluid received in the sub-chamber 162a through the inlet opening 154a flows through the inlet channels 104a to the return tank 180. In addition, the outlet channels 106a are fluidly connected to the sub-chamber 162b. The sub-chamber 162b is configured to collect the fluid from the outlet channels 106a, and the fluid collected in the sub-chamber 162b flows out through the outlet opening 156a.

[0044] In addition, the tubular element 102 can be made of any suitable heat-conductive material and can be arranged such that the battery cell to be cooled can be in indirect contact with the fluid / coolant flowing through the tubular element 102 along a U-shaped flow path. Thus, the fluid flowing through the tubular element 102 can absorb heat from the battery cell and cool the battery cell. In one embodiment, the tubular element 102 can have a flat profile extending along an extension axis 105 in a general direction parallel to the inlet channel 104a and the outlet channel 106a. For example, the flat profile can be understood as a tube cross-section having parallel wide top and bottom walls and two much shorter side walls. In addition, at least a portion of the flat profile of the tubular element 102 can be wavy along the extension axis. For example, the wavy profile of the tubular element 102 can be understood as a tube cross-section having a top wall and a bottom wall and two shorter side walls that are shaped into alternating grooves and ridges.

[0045] In another embodiment, referring to Figure 3 and Figure 4 , the fluid distribution tank 152 can include a substantially U-shaped dividing wall 166a disposed between a first plate 158 and a second plate 160. Two sub-chambers 162a and 162b extend from the connecting opening, thereby forming an arched path for the fluid from the inlet opening 154a to the outlet opening 156a. For example, the cross-sections of the two sub-chambers 162a and 162b can be substantially U-shaped. The volumes of the respective sub-chambers 162a and 162b can be different from each other. In addition, the sub-chamber 162b can surround the other sub-chamber 162a. The sub-chamber 162a is connected to the inlet opening 154a, and the sub-chamber 162b is connected to the outlet opening 156a.

[0046] As Figure 4 shown, the tubular element 102 can include two sets of outlet channels 106a and 106b, a set of inlet channels 104a disposed between the two sets of outlet channels 106a and 106b, and two separating walls 108a and 108b disposed between the two sets of outlet channels 106a and 106b and the set of inlet channels 104a. The set of inlet channels 104a is fluidly connected to the sub-chamber 162a, and the sub-chamber 162a is connected to the inlet opening 154a for the entry of fluid relative to the sub-chamber 162a, and the two sets of outlet channels 106a and 106b are fluidly connected to the sub-chamber 162b from two opposite sides adjacent to the sub-chamber 162a, thereby creating two U-shaped flow paths for the fluid in the tubular element 102. The sub-chamber 162b is connected to the outlet opening 156a for the outflow of fluid relative to the sub-chamber 162b. The fluid flowing through the set of inlet channels 104a can be directed by the return tank 180 to the two sets of outlet channels 106a and 106b to follow the double U-shaped flow path and return through the two sets of outlet channels 106a and 106b.

[0047] Similar to the set of outlet channels 106a, adjacent outlet channels of the set of outlet channels 106b (e.g., outlet channels 106b-1 and 106b-2) are arranged in series and are separated from each other by a second dividing wall 112 in each case. In addition, the cross-sectional areas of at least two individual outlet channels within the set of outlet channels 106b (e.g., outlet channels 106b-1 and 106b-2) can be different from each other. In addition, the cumulative cross-sectional area of the set of inlet channels 104a can be different from the cumulative cross-sectional areas of the two sets of outlet channels 106a and 106b. In addition, the number of inlet channels within the set of inlet channels 104a can be different from the number of outlet channels within the two sets of outlet channels 106a and 106b. For example, the number of inlet channels 104a can be greater than the number of outlet channels 106a and 106b, as Figure 4 shown. The ratio of the number of inlet channels within the set of inlet channels 104a to the number of outlet channels within the two sets of outlet channels 106a and 106b can be in the range of 1.5 to 3.

[0048] In addition, the thickness of the first dividing wall 110 and / or the thickness of the second dividing wall 112 can be less than the thickness of the separating walls 108a and 108b. For example, the thickness of each of the separating walls 108a and 108b can be greater than or equal to the gap between adjacent first dividing walls 110 or the gap between adjacent second dividing walls 112.

[0049] In an alternative embodiment, as Figure 5 and Figure 6 shown, the sub-chamber 162a can be connected to the outlet opening 156a, and the sub-chamber 162b can be connected to the inlet opening 154a. In addition, the tubular element 102 can include two sets of inlet channels 104a and 104b, a set of outlet channels 106a disposed between the two sets of inlet channels 104a and 104b, and two separating walls 108a and 108b disposed between the two sets of inlet channels 104a and 104b and the set of outlet channels 106a, as Figure 6 shown. The two sets of inlet channels 104a and 104b are fluidly connected to the sub-chamber 162b, and the sub-chamber 162b is connected to the inlet opening 154a for the outflow of fluid relative to the sub-chamber 162b. The set of outlet channels 106a is fluidly connected to the sub-chamber 162a, and the sub-chamber 162a is connected to the outlet opening 156a for the outflow of fluid relative to the sub-chamber 162a, thereby forming two U-shaped flow paths for the fluid in the tubular element 102. The fluid flowing through the two sets of inlet channels 104a and 104b can be directed by the return tank 180 to the set of outlet channels 106a to return through the set of outlet channels 106a and flow along the U-shaped flow path.

[0050] Similar to the set of inlet channels 104a, adjacent inlet channels of the set of inlet channels 104b, such as inlet channels 104b-1 and 104b-2, are arranged in series and are separated from each other by a first partition wall 110 in each case. In addition, the cross-sectional areas of at least two individual inlet channels within the set of inlet channels 104b, such as inlet channels 104b-1 and 104b-2, can be different from each other. Furthermore, the cumulative cross-sectional area of the set of inlet channels 104a and 104b can be different from the cumulative cross-sectional area of the set of outlet channels 106a. Additionally, the number of inlet channels within the set of inlet channels 104a and 104b can be different from the number of outlet channels within the set of outlet channels 106a. For example, the number of inlet channels 104a and 104b can be less than the number of outlet channels 106a, as Figure 6 shown. The ratio of the number of outlet channels within the set of outlet channels 106a to the number of inlet channels within the set of inlet channels 104a and 104b can be in the range of 1.5 to 3.

[0051] In another embodiment, referring to Figure 7 and Figure 8 , the fluid distribution tank 152 can include two straight separating walls 166a and 166b between a first plate 158 and a second plate 160 to divide the distribution chamber into three sub-chambers 162a, 162b, and 162c. The three sub-chambers 162a, 162b, and 162c extend from a connection opening 164. For example, the cross-sections of the three sub-chambers 162a, 162b, and 162c can have a rectangular shape. In addition, the separating walls 166a and 166b can protrude from at least one of the first plate 158 and the second plate 160. For example, the separating walls 166a and 166b can be ribs formed by stamping the first plate 158. The separating walls 166a and 166b can be joined to the second plate 160 by a brazing process. Furthermore, the fluid distribution tank 152 can include an inlet opening 154a and two outlet openings 156a and 156b, which can be provided on the first plate 158. The inlet opening 154a can be fluidly connected to the sub-chamber 162c for the entry of fluid relative to the sub-chamber 162c, and the outlet openings 156a and 156b can be fluidly connected to the sub-chambers 162a and 162b for the outflow of fluid relative to the sub-chambers 162a and 162b. Additionally, the volumes of the individual sub-chambers 162a, 162b, and 162c can be different from each other. For example, the volumes of the sub-chambers 162a and 162b can be larger than the volume of the sub-chamber 162c.

[0052] As Figure 8As shown, the tubular element 102 can include two sets of outlet channels 106a and 106b, a set of inlet channels 104a disposed between the two sets of outlet channels 106a and 106b, and two separation walls 108a and 108b disposed between the two sets of outlet channels 106a and 106b and the set of inlet channels 104a. The set of inlet channels 104a is fluidly connected to the sub-chamber 162c, and the sub-chamber 162c is connected to the inlet opening 154a for the entry of fluid relative to the sub-chamber 162c, while the two sets of outlet channels 106a and 106b are respectively fluidly connected to the sub-chambers 162a and 162b, which are connected to the outlet openings 156a and 156b for the outflow of fluid relative to the sub-chambers 162a and 162b, thereby forming two U-shaped flow paths for the fluid in the tubular element 102.

[0053] For example, the cumulative cross-sectional area of the set of inlet channels 104a can be different from the cumulative cross-sectional areas of the two sets of outlet channels 106a and 106b. In addition, the number of inlet channels in the set of inlet channels 104a can be different from the number of outlet channels in the two sets of outlet channels 106a and 106b. For example, the number of inlet channels 104a can be less than the number of outlet channels 106a and 106b, as Figure 8 shown. The ratio of the number of outlet channels in the two sets of outlet channels 106a and 106b to the number of inlet channels in the set of inlet channels 104a can be in the range of 1.5 to 3.

[0054] In an alternative embodiment, referring to Figure 10 and Figure 11 , the fluid distribution tank 152 can include two inlet openings 154a and 154b and one outlet opening 156a, which can be provided on at least one of the first plate 158 and the second plate 160. The inlet openings 154a and 154b can be fluidly connected to the sub-chambers 162a and 162b for the entry of fluid relative to the sub-chambers 162a and 162b respectively, and the outlet opening 156a can be fluidly connected to the sub-chamber 162c for the outflow of fluid relative to the sub-chamber 162c.

[0055] In addition, the tubular element 102 can include two sets of inlet channels 104a and 104b, a set of outlet channels 106a disposed between the two sets of inlet channels 104a and 104b, and two separation walls 108a and 108b disposed between the two sets of inlet channels 104a and 104b and the set of outlet channels 106a, as Figure 11As shown. Two sets of inlet channels 104a and 104b are fluidly connected to sub-chambers 162a and 162b respectively. Sub-chambers 162a and 162b are connected to inlet openings 154a and 154b for the entry of fluid relative to sub-chambers 162a and 162b. The set of outlet channels 106a is fluidly connected to sub-chamber 162c. Sub-chamber 162c is connected to outlet opening 156a for the outflow of fluid relative to sub-chamber 162c, thereby forming two U-shaped flow paths for the fluid in the tubular element 102. The fluid flowing through the two sets of inlet channels 104a and 104b can be directed by the return tank 180 to the set of outlet channels 106a to return through the set of outlet channels 106a and flow along the U-shaped flow paths.

[0056] In addition, the cumulative cross-sectional area of the set of inlet channels 104a and 104b can be different from the cumulative cross-sectional area of the set of outlet channels 106a. In addition, the number of inlet channels in the set of inlet channels 104a and 104b can be different from the number of outlet channels in the set of outlet channels 106a. For example, the number of inlet channels 104a and 104b can be more than the number of outlet channels 106a, as Figure 11 shown. The ratio of the number of inlet channels in the set of inlet channels 104a and 104b to the number of outlet channels in the set of outlet channels 106a can be in the range of 1.5 to 3.

[0057] In one embodiment, as Figure 9 shown, the return tank 180 can include one or more fluid guiding walls 188a and 188b protruding into the return chamber. The fluid guiding walls 188a and 188b are adapted to direct the fluid flowing out of the set of inlet channels 104a to the set of outlet channels 106a and 106b. The fluid guiding walls 188a and 188b can be curved protrusions protruding from at least one of the third plate 182 and the fourth plate 184.

[0058] In any case, the present invention cannot and should not be limited to the embodiments specifically described herein, as there may be other embodiments. The present invention extends to any equivalent devices and any combination of technically operative devices.

Claims

1. A tubular element for a heat exchanger, the tubular element comprising: at least one set of inlet channels; at least one set of outlet channels; and at least one separating wall disposed between the at least one set of inlet channels and the at least one set of outlet channels; wherein the at least one set of inlet channels and the at least one set of outlet channels are arranged asymmetrically with respect to the at least one separating wall.

2. The tubular element according to claim 1, wherein, Adjacent inlet channels of the at least one set of inlet channels are arranged in series and are separated from each other by a first dividing wall in each case.

3. The tubular element according to claim 2, wherein, The thickness of the first dividing wall is less than the thickness of the at least one separating wall.

4. The tubular element according to claim 2, wherein, The thickness of the separating wall is greater than or equal to the gap between adjacent first dividing walls.

5. The tubular element according to claim 1, wherein, Adjacent outlet channels of the at least one set of outlet channels are arranged in series and are separated from each other by a second dividing wall in each case.

6. The tubular element according to claim 5, wherein, The thickness of the second dividing wall is less than the thickness of the at least one separating wall.

7. The tubular element according to claim 5, wherein, The thickness of the separating wall is greater than or equal to the gap between adjacent second dividing walls.

8. The tubular element according to claim 1, wherein, The cross-sectional areas of at least two individual inlet channels within the at least one set of inlet channels are different from each other.

9. The tubular element according to claim 1, wherein, The cross-sectional areas of at least two individual outlet channels within the at least one set of outlet channels are different from each other.

10. The tubular element according to claim 1, wherein, The cumulative cross-sectional area of the at least one set of inlet channels is different from the cumulative cross-sectional area of the at least one set of outlet channels.

11. The tubular element according to claim 1, wherein, The number of inlet channels within the at least one set of inlet channels is different from the number of outlet channels within the at least one set of outlet channels.

12. The tubular element according to claim 11, wherein, The ratio of the number of inlet channels within the at least one set of inlet channels to the number of outlet channels within the at least one set of outlet channels is in the range of 1.5 to 3.

13. The tubular element according to claim 11, wherein, The ratio of the number of outlet channels within the at least one set of outlet channels to the number of inlet channels within the at least one set of inlet channels is in the range of 1.5 to 3.

14. The tubular element according to claim 1, having a flat profile extending along an extension axis in a general direction parallel to the inlet channels and the outlet channels.

15. The tubular element according to claim 14, wherein, At least a portion of the flat profile is wavy along the extension axis.

16. A tank and tube assembly for a heat exchanger, the tank and tube assembly comprising: a tubular element, comprising: at least one set of inlet channels; at least one set of outlet channels configured to be in fluid communication with the at least one set of inlet channels to create at least one U-shaped flow path for fluid through the tubular element; and at least one separating wall disposed between the at least one set of inlet channels and the at least one set of outlet channels, wherein the at least one set of inlet channels and the at least one set of outlet channels are arranged asymmetrically with respect to the at least one separating wall; and a fluid distribution tank coupled to a first end of the tubular element, wherein the fluid distribution tank includes at least one inlet opening fluidly connected to the at least one set of inlet channels and at least one outlet opening fluidly connected to the at least one set of outlet channels.

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