Fluid distribution box for tubular element

Abstract

A fluid distribution box for a heat exchanger, comprising a pair of plates, a first plate and a second plate, which are interconnected to define a distribution chamber between the first plate and the second plate having a connection opening adapted to form a connection between the fluid distribution box and a tubular element of the heat exchanger, and at least one partition wall located between the first plate and the second plate to divide the distribution chamber into at least two sub-chambers. The volumes of the sub-cavities are different from each other.

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 fluid distribution box for a 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 vehicles. The battery pack is the energy source of such vehicles, providing the required power for 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. Therefore, the battery pack must be maintained within a specified operating temperature range for efficient operation. Under hot 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 cold 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 and reduces battery efficiency and durability. Sometimes, due to the battery pack temperature deviating outside the specified temperature range, the battery may be permanently damaged or destroyed, and overheating of the battery cells may even cause fires and other safety-related problems.

[0003] Typical thermal management systems for cooling and heating battery packs rely on multiple subsystems such as coolers, air-fluid heat exchangers, electric heaters, etc. The cooler or air-fluid heat exchanger is suitable for cooling a heat exchange fluid such as a refrigerant or coolant in the battery circuit to cool the battery pack, while the electric heater is suitable for heating 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 battery cells of a battery pack. Such a heat cooling tube arrangement includes a heat cooling tube having two sets of channels / microchannels, including an inlet channel and an outlet channel through which a fluid / coolant flows; and having a central channel configured between the two sets of channels and blocked at both ends; an inlet / outlet box is provided at one end of the cooling tube, and a reflux box / return box is provided at the other end of the cooling tube to allow the fluid to pass through the channels and follow a U-shaped flow path. The heat cooling tube arrangement is suitable for cooling battery cells that are indirectly in contact with the fluid / coolant flowing through the two sets of channels / microchannels and flowing along the U-shaped flow path. However, the existing end boxes of the heat exchanger, especially the inlet / outlet box, include complex component designs and complex joints, which increase the assembly time and manufacturing cost of the existing cooling tube arrangement or heat exchanger.

[0005] Accordingly, there is a need for a simple and robust end box arrangement for a thermal cooling tube that can overcome the above problems associated with the existing end boxes of existing heat exchangers or thermal cooling tube arrangements. In addition, there is a need for a simple and cost-effective tank-tube assembly for U-shaped flow cooling of battery cells in a battery pack. Summary of the Invention

[0006] The present invention discloses a fluid distribution end box for a thermal cooling tube of a heat exchanger, which includes a simple component design, thus reducing the component manufacturing cost and simplifying the assembly process, thereby eliminating the disadvantages of the traditional end boxes of existing cooling tube arrangements. In addition, the proposed end box, especially the fluid distribution box, provides a plurality of compartments with inlet and outlet openings to enable the fluid to follow one or more U-shaped flow paths through a single cooling tube.

[0007] The disclosed end box includes simple joints, thus providing good connection / sealing repeatability while improving the performance, reliability, and service life of the end box, and further improving the performance, reliability, and service life of the thermal cooling tube assembly or heat exchanger. In addition, the disclosed end box provides a larger brazing surface for mating components to be fixed / joined.

[0008] According to an embodiment of the present invention, the disclosed fluid distribution box includes a pair of plates, including a first plate and a second plate, which are connected to each other to define a distribution chamber with a connection opening therebetween. The connection opening is adapted to form a connection between the fluid distribution box and the tubular element of the heat exchanger. The fluid distribution box further includes at least one dividing wall located between the first plate and the second plate for dividing the distribution chamber into at least two sub-chambers, wherein the volumes of the respective sub-chambers are different from each other.

[0009] The at least one dividing wall projects from at least one of the first plate and the second plate. In addition, the at least one dividing wall is coupled to the first plate and the second plate. For example, at least one of the first plate and the second plate may be a stamped metal plate. For example, the at least one dividing wall may be a stamped rib extending from the first plate. In addition, the first plate, the second plate, and the at least one dividing wall may be coupled to each other by a joining process (such as but not limited to brazing).

[0010] At least one of the first plate and the second plate includes at least one inlet opening for fluid to enter the distribution chamber. At least one of the first plate and the second plate includes at least one outlet opening for fluid to flow out of the distribution chamber. The at least one inlet opening and the at least one outlet opening are configured such that at least one of the at least two sub-chambers is fluidly connected to the at least one inlet opening, and at least one of the at least two sub-chambers is fluidly connected to the at least one outlet opening.

[0011] In addition, the first plate and the second plate have side edges that protrude towards each other. The side edge of the first plate is adjacent to the side edge of the second plate. In addition, the adjacent side edges of the first plate and the second plate can be crimped to each other.

[0012] In one embodiment, the at least two sub-chambers extend from the connection opening. The cross-section of the at least two sub-chambers can have a rectangular shape. In addition, the at least one dividing wall can be straight.

[0013] In another embodiment, the at least two sub-chambers extend from the connection opening to form an arched passage for the fluid from the at least one inlet to the at least one outlet. In addition, the at least one dividing wall can be substantially U-shaped.

[0014] According to another embodiment, the present invention discloses a header-tube assembly for a heat exchanger. The header-tube assembly includes a tubular element that includes at least one set of inlet channels and at least one set of outlet channels, the at least one set of outlet channels being configured to be in fluid communication with the at least one set of inlet channels to establish at least one U-shaped flow path for the fluid through the tubular element; and a fluid distribution header, such as the header disclosed above, that is coupled to a first end of the tubular element. The fluid distribution header includes a first plate and a second plate that are connected to each other to define a distribution chamber having a connection opening to establish a connection between the fluid distribution header and the tubular element; and includes at least one dividing wall for dividing the distribution chamber into at least two sub-chambers, wherein the volumes of the respective sub-chambers are different from each other.

[0015] In this specification, some elements or parameters may be indexed, such as a first element and a second element. In this 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 because these terms can be interchanged without violating the present invention. In addition, such indexing does not imply any order in the installation or use of the elements of the present invention. Description of the Drawings

[0016] Other features, details, and advantages of the present invention can be derived from the following description of the present invention. By referring to the following detailed description in conjunction with the accompanying drawings, a more comprehensive understanding of the present invention and its many attendant advantages will be readily obtained when a deeper understanding of the present invention is achieved, wherein:

[0017] Figure 1 A header-tube assembly having one U-shaped flow path for a heat exchanger according to an embodiment of the present invention is shown;

[0018] Figure 2 Shown is Figure 1 the tubular element of the header-tube assembly having one set of inlet channels and one set of outlet channels;

[0019] Figure 3 shows a tank tube assembly having two U-shaped flow channels according to an embodiment of the present invention;

[0020] Figure 4 shows Figure 3 the tubular element of the tank tube assembly having a set of inlet channels and two sets of outlet channels;

[0021] Figure 5 shows a tank tube assembly according to an embodiment of the present invention, the assembly having a fluid distribution tank with an inlet opening and an outlet opening for implementing two U-shaped flow channels;

[0022] Figure 6 shows Figure 5 the tubular element of the tank tube assembly having two sets of inlet channels and a set of outlet channels;

[0023] Figure 7 shows a tank tube assembly according to an embodiment of the present invention, the assembly having a fluid distribution tank with an inlet opening and two outlet openings;

[0024] Figure 8 shows Figure 7 the tubular element of the shown tank tube assembly having a set of inlet channels and two sets of outlet channels;

[0025] Figure 9 shows a tank tube assembly according to an embodiment of the present invention, the assembly having a reflux tank with fluid guiding walls;

[0026] Figure 10 shows a tank tube assembly according to an embodiment of the present invention, the assembly having a fluid distribution tank with two inlet openings and an outlet opening;

[0027] Figure 11 shows Figure 10 the tubular element of the tank tube assembly in

[41] having two sets of inlet channels and a set of outlet channels. Detailed Description

[0028] It must be noted that the drawings disclose the present invention in sufficient detail and, if necessary, these drawings help to better define the present invention. However, the present invention should not be limited to the embodiments disclosed in the specification.

[0029] The present invention will be illustrated by way of examples of heat exchanger tank tube assemblies in the following description and drawings, wherein each tank tube assembly is formed by assembling a tubular element and one or more end tanks fitted at opposite ends of the tubular element to create one or more U-shaped flow paths for a heat exchange fluid for cooling battery cells of an electric and / or hybrid vehicle. The end tanks of the tank tube assembly, such as fluid distribution tanks, employ a simple component design, thus reducing component manufacturing costs and simplifying the assembly process. In addition, the disclosed tank tube assembly contributes to low resistance flow characteristics and does not significantly cause pressure drop. Moreover, the disclosed tank tube assembly can be conveniently retrofitted with the battery cells in a battery pack, thereby achieving optimal space utilization, i.e., an efficient cooling tank tube assembly density between the battery cells and leaving space gaps above and below the battery modules.

[0030] 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.

[0031] Referring to Figure 1 、 3 Figures 5, 7, 9, and 10, the present invention discloses a tank tube assembly 150 for a heat exchanger for cooling battery cells of a battery pack. For example, the battery pack can be mounted on an electric or hybrid vehicle, wherein the battery cells of the battery pack can be rechargeable cylindrical batteries. The tank tube assembly 150 includes a tubular element 102, a fluid distribution tank 152 coupled to a first end 103a of the 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 at which the return tank 180 returns / diverts the fluid flowing out of the tubular element 102 so that it follows a U-shaped flow path through the tubular element 102. The tubular element 102 includes at least one set of inlet channels 104a, 104b and at least one set of outlet channels 106a, 106b that are configured to be in fluid communication with the inlet channels 104a, 104b to create at least one U-shaped flow path for the fluid through the tubular element 102. For example, all components of the tank tube assembly 150 can be interconnected by suitable joining techniques, such as but not limited to soldering techniques.

[0032] The fluid distribution box 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 and second plates may be joined by a brazing process. The connection opening 164 is adapted to form a connection between the fluid distribution box 152 and the tubular element 102. The connection opening 164 of the fluid distribution box 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 fluid to enter 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 fluid to flow out of the distribution chamber. Further, at least one wall 166a, 166b may 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 may be a stamped metal plate. Additionally, the at least one dividing wall 166a, 166b may be a rib extending from at least one of the first plate 158 and the second plate 160.

[0033] In addition, the first plate 158 and the second plate 160 may have side edges 168 on two or more sides (e.g., 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 may be joined to each other. Additionally, the adjacent side edges 168 of the first plate 158 and the second plate 160 may be crimped to each other.

[0034] Furthermore, the return box 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 a hole 186, thereby forming a connection between the return box 180 and the tubular element 102. For example, the third plate 182 and the fourth plate 184 may be joined by a brazing process. The hole 186 of the return box 180 is adapted to receive and securely hold the second end / return end 103b of the tubular element 102. In addition, the return chamber of the return box 180 is in fluid communication with the inlet and outlet channels 104a, 104b, 106a, 106b of the tubular element 102 through the hole 186 such that the fluid flowing through the inlet channels 104a, 104b is collected in the return chamber and the fluid is further directed / supplied to the outlet channels 106a, 106b to follow a U-shaped flow path in the tubular element 102. In one embodiment, the cross-section of the return box 180 may have a rectangular shape. In another embodiment, the cross-section of the return box 180 may have a generally U-shaped shape.

[0035] In addition, the third plate 182 and the fourth plate 184 may each have side edges 190 on two or more sides (e.g., three sides). The side edges 190 of the third plate 182 and the fourth plate 184 protrude towards each other and may be coupled 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.

[0036] In one embodiment, as Figure 1 shown, the fluid distribution box 152 may include a partition wall 166a located between the first plate 158 and the second plate 160 to divide the distribution chamber into two sub-chambers 162a and 162b. The two sub-chambers 162a and 162b extend from the connection opening 164. For example, the cross-sections of the two sub-chambers 162a and 162b may have a rectangular shape, and the partition wall 166a may be straight. In addition, the partition wall 166a may protrude from at least one of the first plate 158 and the second plate 160. For example, the partition wall 166a may protrude from the first plate 158 and be formed by a stamping process. The partition 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 fluidly connected to the sub-chamber 162a to allow fluid to enter the sub-chamber 162a, and the outlet opening 156a may be fluidly connected to the sub-chamber 162b to allow fluid to flow out of 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.

[0037] In one embodiment, as Figure 2 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 partition wall 108a. The partition wall may be configured to be close to the longitudinal side wall of the tubular element 102 near the outlet channels 106a. In addition, adjacent inlet channels, such as inlet channels 104a-1 and 104a-2, are arranged in series and separated from each other by a first isolation wall 110. The thickness of the first isolation wall 110 is less than the thickness of the partition wall 108a. Similarly, adjacent outlet channels, such as outlet channels 106a-1 and 106a-2, are arranged in series and separated from each other by a second isolation wall 112. The thickness of the second isolation wall 112 is less than the thickness of the partition wall 108a. For example, the thickness of the partition wall 108a may be greater than or equal to the gap between adjacent first isolation walls 110 or the gap between adjacent second isolation walls 112.

[0038] In addition, the cross-sectional areas of at least two separate inlet channels (e.g., channels 104a-1 and 104a-N within the set of inlet channels 104a) can be different from each other. In addition, the cross-sectional areas of at least two separate outlet channels (e.g., outlet channels 106a-1 and 106a-2 within the set of outlet channels 106a) 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 area of the set of outlet channels 106a. 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 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 can be in the range of 1.5 to 3.

[0039] In addition, the outlet channel 106a is configured to be in fluid communication with the inlet channel 104a at the second end 103b through the return box 180 to establish a U-shaped flow path of fluid through the tubular element 102. The inlet channel 104a is 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 channel 104a towards the return box 180. In addition, the outlet channel 106a is fluidly connected to the sub-chamber 162b. The sub-chamber 162b is configured to collect fluid from the outlet channel 106a, and the fluid collected in the sub-chamber 162b further flows out through the outlet opening 156a.

[0040] In addition, the tubular element 102 can be made of any suitable heat-conducting 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 the 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 the extension axis 105, which is parallel to the general direction of 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 and bottom wall and two shorter side walls shaped as alternating grooves and ridges.

[0041] In another embodiment, reference Figure 3 and Figure 4, the fluid distribution box 152 may include a generally U-shaped dividing wall 166a disposed between the first plate 158 and the second plate 160. Two sub-chambers 162a and 162b extend from the connecting opening, thereby forming an arched path for fluid from the inlet opening 154a to the outlet opening 156a. For example, the cross-sections of the two sub-chambers 162a and 162b may be generally U-shaped. The volumes of the respective sub-chambers 162a and 162b may be different from each other. In addition, the sub-chamber 162b may 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.

[0042] As Figure 4 shown, the tubular element 102 may 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 dividing 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 so that fluid enters the sub-chamber 162a, and the two sets of outlet channels 106a and 106b are fluidly connected to the two opposite sides adjacent to the sub-chamber 162a and the sub-chamber 162b, thereby creating two U-shaped flow paths for fluid in the tubular element 102. The sub-chamber 162b is connected to the outlet opening 156a so that fluid flows out of the sub-chamber 162b. The fluid flowing through the set of inlet channels 104a may be guided by the return box 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.

[0043] Similar to the set of outlet channels 106a, the adjacent outlet channels in the set of outlet channels 106b, such as the outlet channels 106b-1 and 106b-2, are arranged in series and are separated from each other by the second partition wall 112 in each case. In addition, the cross-sectional areas of at least two individual outlet channels (such as the outlet channels 106b-1 and 106b-2) within the set of outlet channels 106b 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 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 may be different from the number of outlet channels within the two sets of outlet channels 106a and 106b. For example, as Figure 4 shown, the number of inlet channels 104a may be more than the number of outlet channels 106a and 106b. 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 may be in the range of 1.5 to 3.

[0044] In addition, the thickness of the first partition wall 110 and / or the thickness of the second partition wall 112 may be less than the thickness of the partition walls 108a and 108b. For example, the thickness of each of the partition walls 108a and 108b may be greater than or equal to the gap between adjacent first partition walls 110 or the gap between adjacent second partition walls 112.

[0045] In another embodiment, as Figure 5 and Figure 6 shown, the sub-chamber 162a may be connected to the outlet opening 156a, and the sub-chamber 162b may be connected to the inlet opening 154a. In addition, the tubular element 102 may 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 partition 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 so that fluid flows out of 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 so that fluid flows out of the sub-chamber 162a, thereby establishing two U-shaped flow paths for the fluid within the tubular element 102. The fluid flowing through the two sets of inlet channels 104a and 104b may be guided by the reflux box 180 towards the set of outlet channels 106a to flow back through the set of outlet channels 106a and follow the U-shaped flow path.

[0046] Similar to the set of inlet channels 104a, the adjacent inlet channels in the set of inlet channels 104b, such as the inlet channels 104b-1 and 104b-2, are arranged in series and are separated from each other by the first partition wall 110 in each case. In addition, the cross-sectional areas of at least two individual inlet channels (such as the inlet channels 104b-1 and 104b-2) within the set of inlet channels 104b may be different from each other. In addition, the cumulative cross-sectional area of the two sets of inlet channels 104a and 104b 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 two sets of inlet channels 104a and 104b may be different from the number of outlet channels within the set of outlet channels 106a. For example, as Figure 6 shown, the number of inlet channels 104a and 104b may be less than the number of outlet channels 106a. The ratio of the number of outlet channels within the set of outlet channels 106a to the number of inlet channels within the two sets of inlet channels 104a and 104b may be in the range of 1.5 to 3.

[0047] In another embodiment, referring to Figure 7 andFigure 8 ,The fluid distribution box 152 may include two straight partition walls 166a and 166b between the first plate 158 and the 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 the connection opening 164. For example, the cross-sections of the three sub-chambers 162a, 162b, and 162c may have a rectangular shape. In addition, the partition walls 166a and 166b may protrude from at least one of the first plate 158 and the second plate 160. For example, the partition walls 166a and 166b may be ribs formed by stamping the first plate 158. The partition walls 166a and 166b may be joined to the second plate 160 by a brazing process. In addition, the fluid distribution box 152 may include an inlet opening 154a and two outlet openings 156a and 156b, which may be provided on the first plate 158. The inlet opening 154a may be fluidly connected to the sub-chamber 162c for fluid to flow into the sub-chamber 162c, while the outlet openings 156a and 156b may be fluidly connected to the sub-chambers 162a and 162b for fluid to flow out of the sub-chambers 162a and 162b. In addition, the volumes of the respective sub-chambers 162a, 162b, and 162c may be different from each other. For example, the volumes of the sub-chambers 162a and 162b may be larger than the volume of the sub-chamber 162c.

[0048] As Figure 8 shown, the tubular element 102 may 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 partition 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 fluid to flow into 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, and the sub-chambers 162a and 162b are connected to the outlet openings 156a and 156b for fluid to flow out of the sub-chambers 162a and 162b, thereby establishing two U-shaped flow paths for the fluid within the tubular element 102.

[0049] For example, the cumulative cross-sectional area of the set of inlet channels 104a may 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 may be different from the number of outlet channels within the set of outlet channels 106a and 106b. For example, as Figure 8As shown, the number of inlet channels 104a may be less than the number of outlet channels 106a and 106b. The ratio of the number of outlet channels within the set of outlet channels 106a and 106b to the number of inlet channels within the set of inlet channels 104a may be in the range of 1.5 to 3.

[0050] In another embodiment, referring to Figure 10 and Figure 11 the fluid distribution box 152 may include two inlet openings 154a and 154b and one outlet opening 156a, which may be provided on at least one of the first plate 158 and the second plate 160. The inlet openings 154a and 154b may be fluidly connected to the sub-chambers 162a and 162b respectively for fluid to enter the sub-chambers 162a and 162b, and the outlet opening 156a may be fluidly connected to the sub-chamber 162c for fluid to flow out of the sub-chamber 162c.

[0051] In addition, as Figure 11 shown, the tubular element 102 may 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 partition walls 108a and 108b disposed between the inlet channels 104a and 104b and the outlet channels 106a. The two sets of inlet channels 104a and 104b are fluidly connected to the sub-chambers 162a and 162b respectively, and the sub-chambers 162a and 162b are further connected to the inlet openings 154a and 154b for fluid to enter the sub-chambers 162a and 162b. The set of outlet channels 106a is fluidly connected to the sub-chamber 162c, and the sub-chamber 162c is connected to the outlet opening 156a for fluid to flow out of the sub-chamber 162c, thereby establishing 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 may be directed by the reflux box 180 to the set of outlet channels 106a, causing it to reflux through the set of outlet channels 106a and follow the U-shaped flow path.

[0052] In addition, the cumulative cross-sectional area of the set of inlet channels 104a and 104b 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 and 104b may be different from the number of outlet channels within the set of outlet channels 106a. For example, as Figure 11 shown, the number of inlet channels 104a and 104b may be more than the number of outlet channels 106a. The ratio of the number of inlet channels within the set of inlet channels 104a and 104b to the number of outlet channels within the set of outlet channels 106a may be in the range of 1.5 to 3.

[0053] In one embodiment, as Figure 9As shown, the return box 180 may include one or more fluid guiding walls 188a and 188b that project into the return chamber. The fluid guiding walls 188a and 188b may be adapted to direct the fluid flowing out of the set of inlet channels 104a towards the set of outlet channels 106a and 106b. The fluid guiding walls 188a and 188b may be curved protrusions that project from at least one of the third plate 182 and the fourth plate 184.

[0054] In any case, the present invention cannot and should not be limited to the embodiments specifically described in this document, as there may be other embodiments. The present invention should extend to any equivalent means and any combination of technically feasible means.

Claims

1. A fluid distribution box for a tubular element of a heat exchanger, the fluid distribution box comprising: A pair of plates, including a first plate and a second plate, the plates being coupled to each other to define a distribution chamber having a connection opening therebetween, the connection opening being adapted to form a connection between the fluid distribution box and the tubular element; And At least one dividing wall located between the first plate and the second plate to divide the distribution chamber into at least two sub-chambers, wherein the volumes of the respective sub-chambers are different from each other.

2. The fluid distribution box according to claim 1, wherein, The at least one dividing wall projects from at least one of the first plate and the second plate.

3. The fluid distribution box according to claim 1, wherein The at least one dividing wall is coupled to the first plate and the second plate.

4. The fluid distribution box according to claim 1, wherein At least one of the first plate and the second plate includes at least one inlet opening for fluid to enter the distribution chamber, and at least one of the first plate and the second plate includes at least one outlet opening for fluid to exit the distribution chamber.

5. The fluid distribution box according to claim 4, wherein At least one of the at least two sub-chambers is fluidly connected to the at least one outlet opening.

6. The fluid distribution box according to claim 4, wherein, At least one of the at least two sub-chambers is fluidly connected to the at least one inlet opening.

7. The fluid distribution box according to claim 1, wherein, The first plate and the second plate have side edges that project towards each other, and wherein the side edge of the first plate abuts the side edge of the second plate.

8. The fluid distribution box according to claim 7, wherein The abutting side edges of the first plate and the second plate are crimped to each other.

9. The fluid distribution box according to claim 1, wherein, At least one of the first plate and the second plate is a stamped metal plate.

10. The fluid distribution box according to claim 1, wherein, The at least two sub-chambers extend from the connection opening, and the cross-section of the at least two sub-chambers has a rectangular shape.

11. The fluid distribution box according to claim 1, wherein, The at least one dividing wall is straight.

12. The fluid distribution box according to claim 4, wherein, The at least two sub-chambers extend from the connection opening to form an arched passage for fluid from the at least one inlet to the at least one outlet.

13. The fluid distribution box according to claim 12, wherein, The at least one dividing wall is generally U-shaped.

14. A box-tube assembly for a heat exchanger, the box-tube assembly comprising: A tubular element including at least one set of inlet channels and at least one set of outlet channels, the at least one set of outlet channels being configured to be in fluid communication with the at least one set of inlet channels to establish at least one U-shaped flow path for fluid through the tubular element; And A fluid distribution box coupled to a first end of the tubular element; Wherein, the fluid distribution box includes: A pair of plates, including a first plate and a second plate, the plates being coupled to each other to define a distribution chamber having a connection opening therebetween, the connection opening being adapted to form a connection between the fluid distribution box and the tubular element; and At least one dividing wall located between the first plate and the second plate to divide the distribution chamber into at least two sub-chambers, wherein the volumes of the respective sub-chambers are different from each other.

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