Plate assembly and heat exchanger

Abstract

A plate assembly (10) for a heat exchanger (100) comprises a first plate (10a), a second plate (10b) and a distribution plate (10c) sandwiched between the first plate (10a) and the second plate (10b). The first plate (10a) comprises a first planar portion (12a) and a first peripheral wall (14a). The second plate (10b) comprises a second planar portion (12b) and second peripheral wall (14b). The distribution plate (10c) comprises a third planar portion (12c) arranged between the first and second planar portions (12a) and (12b) adapted to be arranged spaced from each. The distribution plate (10c) comprises at least one corrugation (14c) adapted to direct fluid flow along the distribution plate (10c), limit first fluid flow to the first and the second peripheral walls (14a) and (14b) and form secure joints between the first plate (10a) and the second plate (10b).

Description

TECHNICAL FIELD

[0001] The present invention relates to a heat exchanger, more particularly, the present invention relates to a plate type heat exchanger for use in a vehicle.BACKGROUND

[0002] A vehicle generally includes various heat exchangers such as for example, a radiator, a condenser, an evaporator and a charged air cooler. With technological shift from conventional internal combustion engine driven vehicles to electric vehicles, there is a need for battery cooling and dedicated heat exchangers for battery cooling such as for example a chiller. The chiller is for supplying cooled coolant to a battery-cooling module that in turn extracts thermal energy from the batteries by being in contact with the batteries. Generally, the chiller is a plate type heat exchanger. The plate type heat exchangers provide several advantages compared to conventional tube type heat exchangers. For example, the plate type heat exchangers are compact, space efficient, exhibit enhanced heat transfer efficiency compared to tube type heat exchangers. Further, the plate type heat exchangers are cost effective and environment friendly compared to the tube type heat exchangers. Further, the plates of the plate type heat exchangers are formed by easy, repeatable, and cost effective stamping process. The plate type heat exchangers offer high exchange area for heat exchange fluids. The plate type heat exchangers can be formed of recyclable aluminum material and can be formed from single material instead different parts of different materials. The plate type heat exchangers have robust construction and withstand high pressures due to the plates being connected at multiple points. However, there are challenges associated with use of plate type heat exchangers.

[0003] The plate type heat exchanger includes multiple plates, a first set of inlet and outlet ports and a second set of inlet and outlet ports. The plate type heat exchanger optionally includes multiple turbulators. The multiple plates are stacked with respect to each other and joined to each other to define first flow passages and second flow passages adjacent to the first fluid flow passages for heat exchange between first and second fluid flowing through the first and second flow passages. In case the heat exchanger is a chiller, the first flow passages are for refrigerant flow and the second flow passages are for coolant flow. Each plate comprises a first set of apertures and a second set of apertures. The first set of apertures configure the first set of channels in fluid communication with first flow passages and the second set of apertures configure the second set of channels in fluid communication with second flow passages. The first set of inlet and outlet ports are for ingress and egress of first fluid with respect to the first flow passages. The second set of inlet and outlet ports are for ingress and egress of second fluid with respect to the second flow passages.

[0004] With increasing environmental concern, environmentally friendly refrigerants such as R744 are preferred over other synthetic refrigerants, particularly, Hydro-fluoro-olefin based refrigerants such as R1234yf. The use of R744 in vehicle air conditioning system exhibits several advantages such as non-toxicity, non-flammability, and inexpensive. However, the use of carbon dioxide as refrigerant face several challenges. Particularly, the elements, such as compressor and heat exchangers, such as for example, chiller interacting with the high-pressure carbon dioxide as refrigerant should be capable of withstanding the high pressures. Since the chiller is formed by joining plates, wherein adjacent plates are joined to create refrigerant flow passages there-between, there are chances of refrigerant leakage due to mechanical failures such as cracks and adjacent plates separating from each, particularly, at weaker sections, where the connection between the plates is weak and when subjected to high pressures. Further, the conventional chiller face challenges in directing the flow along the plates to achieve controlled refrigerant flow to achieve high efficiency and performance. Further, the conventional plate type heat exchangers, chiller fails under salt spray / corrosion testing.

[0005] Accordingly, there is a need for a plate type heat exchanger, particularly, a chiller formed by joining multiple plates, wherein adjacent plates can be securely joined to each other to configure refrigerant flow passages there between. The joints between the adjacent plates, particularly, the large unsupported areas between the adjacent plates act as weak points that are prone to mechanical failures. Particularly, there is a need for chiller formed by joining multiple plates, wherein the adjacent plates configuring fluid flow passages are securely held together to withstand high pressure exerted by high pressure refrigerant flowing between the adjacent plates configuring refrigerant flow passages. Further, there is a need for a plate type heat exchanger, wherein the plates configuring the plate type heat exchanger are capable of directing high-pressure refrigerant away from weaker sections of the heat exchanger, thereby improving durability and service life of the plate heat exchanger. Furthermore, there is a need for a plate type heat exchanger, wherein the plates configuring the plate type heat exchanger control refrigerant flow along the plates to for improved heat exchanger to achieve high efficiency and performance of the plate type heat exchanger. Furthermore, there is a need for a plate type heat exchanger with such arrangement of plates that renders it challenging for corrosion to penetrate through sidewalls and damage the plate heat exchanger, thereby enabling the plate type heat exchanger to pass the corrosion test.SUMMARY

[0006] A plate assembly for a heat exchanger is disclosed in accordance with an embodiment of the present invention. The plate assembly comprises a first plate, a second plate and a distribution plate. The first plate comprises a first planar portion and a first peripheral wall. The second plate comprises a second planar portion and a second peripheral wall. The second planar portion is adapted to be arranged spaced from the first planar portion. The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate adapted to define first flow passage between the first and second planar portions. The first and the second peripheral walls adapted to interact with each other to maintain the first and the second planar portions spaced from each other to receive the distribution plate between the first and second plate. The distribution plate comprises at least one corrugation formed on the third planar portion. The at least one corrugation adapted to direct fluid flow along the distribution plate, limit first fluid flow to the first and the second peripheral walls and facilitate forming of secure joints between the first plate and the second plate.

[0007] Generally, the first plate comprises a first set of apertures and a second set of apertures aligned to a first set of holes and a second set of holes formed on the second plate and a first set of openings and a second set of openings formed on the distribution plate to configure a first manifold and a second manifold.

[0008] Particularly, at least a portion of at least one corrugations is arranged proximal to at least a portion of at least one opening of at least one of the first set of openings and the second set of openings.

[0009] In accordance with an embodiment of the present invention, outer sides of the first peripheral wall fits within inner sides of the second peripheral wall at a distance from the base of the second peripheral wall.

[0010] Specifically, at least one first corrugation is arranged along the first and the second peripheral walls of the respective first and the second plate to limit flow of first fluid to the first and second peripheral walls.

[0011] Further, at least one second corrugation provided at central portion of the distribution plate is adapted to define outline for flow of first fluid along the central portion of the distribution plate.

[0012] Particularly, the corrugations define four passes along the distribution plate.

[0013] More specifically, the corrugations configures micro-channels for flow of first fluid along the distribution plate.

[0014] Further, the distribution plate comprises additional protruding features formed on the planar portion thereof and adapted to provide sufficient contact between the distribution plate and at least one of the first plate and the second plate to configure secure joint there between.

[0015] Generally, at least one of the first plate and the second plate comprises a corresponding rib extending along at least a portion of the length of the plate and adapted to define u-flow along the plate.

[0016] Specifically, the rib emanates from a portion of the first peripheral wall proximal to the first set of apertures and terminates before another portion of the first peripheral wall proximal to the second set of apertures to configure u-flow of second fluid along the first plate.

[0017] More specifically, the rib is adapted to prevent flow through the gap "G" between the innermost corrugations defining the u-flow between the second pass R2 and the third pass R3 of the first fluid along the distribution plate.

[0018] Also is disclosed a heat exchanger in accordance with an embodiment of the present invention. The heat exchanger is for heat exchange between a first fluid and a second fluid and comprises a plurality of plate assemblies, a first set of inlet and outlet ports and a second set inlet and outlet ports. The plate assemblies are stacked with respect to each other to configure a core of the heat exchanger. Each plate assembly being as disclosed above and adapted to define first flow passages between the first and the second plates thereof. Further, each plate assembly adapted to define second flow passages with adjacent fluid assemblies on opposite sides thereof. The first flow passages corresponding to the multiple plate assemblies being in fluid communication with a first manifold. Similarly, the second flow passages corresponding to the multiple plate assemblies being in fluid communication with a second manifold. The first set of inlet and outlet ports being in fluid communication with a first manifold for ingress and egress of first fluid with respect to the first flow passages configured within the heat exchanger. Similarly, the second set inlet and outlet ports being in fluid communication with a second manifold for ingress and egress of second fluid with respect to the second flow passages configured within the heat exchanger.

[0019] In accordance with an embodiment of the present invention, the first manifold is formed by aligned and engaging second set of openings formed on the distribution plates of the corresponding plate assemblies. The second manifold is formed by the aligned and engaging first set of apertures and a first set of holes formed on the respective first plates and the second plates of the corresponding plate assemblies configuring the core.

[0020] More specifically, the plate assembly is adapted to configure second flow passage between the first plate thereof and a second plate of a first adjacent plate assembly. Further, the plate assembly adapted to configure second flow passage between the second plate thereof and a first plate of a second adjacent plate assembly opposite to the first adjacent plate assembly.

[0021] Furthermore, the heat exchanger comprises a plurality of turbulators arranged between adjacent plate assemblies and adapted retard flow through second flow passages. The turbulators comprising a first set of holes and a second set of holes ) aligned with a first set of apertures and a second set of apertures formed on the first plate.

[0022] Still further, the heat exchanger comprises a pair of top and bottom plates and an additional pair of reinforcement plates. The plate assemblies configuring the core are arranged between the top and bottom plates. The top and bottom plates are arranged between the pair of reinforcement plates.BRIEF DESCRIPTION

[0023] Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained, as the same becomes better understood by reference to the following description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates an exploded view of a plate assembly in accordance with an embodiment of the present invention; FIG. 2 illustrates a perspective view of a first plate of the plate assembly of FIG. 1; FIG. 3 illustrates a perspective view of a second plate of the plate assembly of FIG. 1; FIG. 4 illustrates a perspective view of a distribution plate of the plate assembly of FIG. 1; FIG. 5 illustrates a top view of the distribution plate of FIG. 4 depicting four passes of a refrigerant flow along the distribution plate. FIG. 6 illustrates a perspective view of a heat exchanger, particularly, a chiller in accordance with an embodiment of the present invention. FIG. 7 illustrates a side view of the chiller of FIG. 6. FIG. 8 illustrates a sectional view of the chiller along section line A-A' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line A-A'. FIG. 9 illustrates a sectional view of the chiller along section line B-B' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line B-B'. FIG. 10 illustrates a sectional view of the chiller along section line C-C' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line C-C'. FIG. 11 illustrates a perspective view of the turbulators arranged between adjacent plate assemblies configuring the chiller of FIG.6. DETAILED DESCRIPTION

[0024] It must be noted that the figures disclose the invention in a detailed enough way to be implemented, the figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0025] In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements that are similar but not identical. No idea of priority should be inferred from such indexation, as these may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

[0026] The present is explained with example of a chiller, wherein the chiller comprises multiple plate assemblies stacked with respect to one another. Each of the plate assemblies comprises a distribution plate sandwiched between a first plate and a second plate. The first plate comprises a first planar portion and a first peripheral wall. The second plate comprises a second planar portion and a second peripheral wall. The second planar portion is adapted to be arranged spaced from the first planar portion. The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate adapted to define first flow passage between the first and second planar portions. The first and the second peripheral walls are adapted to interact with each other to maintain the first and the second planar portions spaced from each other to receive the distribution plate between the first and second plate. The distribution plate comprises at least one corrugation formed on the third planar portion. The at least one corrugation adapted to direct fluid flow along the distribution plate, limit first fluid flow to the first and the second peripheral walls and facilitate forming of secure joints between the first plate and the second plate. The plate assembly is adapted to configure second flow passages with adjacent plate assemblies. With such configuration, the first flow passage for refrigerant flow is arranged between second flow passages for coolant flow to configure heat exchange between refrigerant and coolant.

[0027] However, the present invention is also applicable to any heat exchanger used in vehicular or non-vehicular environment, wherein it is required to configure secure brazing connection between distribution plate and the first and second plates configuring the plate assembly forming the heat exchanger and wherein it is required to limit fluid flow to weaker sections of the heat exchanger. The weaker sections of the heat exchanger could be for example the sides of the heat exchanger formed by staking together the peripheral walls of the first and second plates. Further, the present invention is also applicable wherein high-pressure fluid is introduced between plates configuring the heat exchanger and the plates are required to be securely joined to each other to withstand high pressure of the fluid flowing between the plates.

[0028] The present disclosure envisages a heat exchanger, particularly, a chiller 100 formed by assembling a plurality of plate assemblies 10. FIG. 1 illustrates an exploded view of a plate assembly 10 in accordance with an embodiment of the present invention. The plate assembly 10 includes a first plate 10a, a second plate 10b and a distribution plate 10c. The distribution plate 10c is arranged between the first plate 10a and the second plate 10b.

[0029] FIG. 2 illustrates a perspective view of the first plate 10a. The first plate 10a comprises a first planar portion 12a and a first peripheral wall 14a. The first peripheral wall 14a extending along the periphery of the first planar portion 12a is either orthogonally extending or inclined with respect to the first planar portions 12a. The first plate 10a comprises a first set of apertures 16a and a second set of apertures 18a formed along opposite lateral sides thereof.

[0030] FIG. 3 illustrates a perspective view of the second plate 10b. The second plate 10b comprises a second planar portion 12b and a second peripheral wall 14b. The second planar portion 12b is adapted to be arranged spaced from the first planar portion 12a. The second peripheral wall 14b extending along the periphery of the second planar portion 12b. The second peripheral wall 14b is either orthogonally extending or inclined with respect to the second planar portion 12b. The first and the second peripheral walls 14a and 14b are adapted to interact with each other to maintain the first and the second planar portions spaced from each other. In accordance with an embodiment of the present invention as illustrated in enlarged sectional view of the heat exchanger depicted in FIG. 8, outer sides of the first peripheral wall 14a fits within inner sides of the second peripheral wall 14b at a distance from the base of the second peripheral wall 14b. Such arrangement of the first peripheral wall 14a interacting with the second peripheral wall 14b maintains the first planar portion 12a and the second planar portion 12b spaced apart from each other. The stacked peripheral walls 14a and 14b of the first and second plates 10a and 10b define the sidewalls of a core 100a of the chiller 100. Due to such configuration of the sidewalls of the chiller 100 formed by staggered peripheral walls 14a and 14b, the sides of the chiller are comparatively weaker than top and bottom sides of the chiller 100.

[0031] The second plate 10b comprises a first set of holes 16b and a second set of holes 18b formed along opposite lateral sides of the second plate 10b. Generally, at least one of the first plate 10a and the second plate 10b comprises a corresponding rib 19a, 19b extending along at least a portion of the length of the plate 10a, 10b and adapted to define u-flow along the plate 10a, 10b. Specifically, the rib 19a emanates from a portion of the first peripheral wall 14a proximal to the second set of apertures 18a and terminates before another portion of the first peripheral wall 14a proximal to the first set of apertures 16a to configure u-flow of second fluid, particularly, coolant along the first plate 10a. More specifically, the rib 19a is adapted to prevent flow through the gap "G" between the innermost corrugations 14c defining the u-flow between the second pass R2 and the third pass R3 of the first fluid along the distribution plate 10c.

[0032] FIG. 4 illustrates a perspective view of the distribution plate 10c. The distribution plate 10c comprises a third planar portion 12c arranged between the first planar portion 12a and the second planar portion 12b of the plate assembly 10. The distribution plate 10c is adapted to define first flow passage 12 between the first planar portion 12a and the second planar portion 12b. The distribution plate 10c is arranged between the first plate 10a and the second plate 10b to define the first flow passages 12 between the distribution plate 10c and the respective first and second plates 10a and 10b. Specifically, the distribution plate 12c received between spaced apart first planar portion 12a and the second planar portion 12b of the first and the second plate 10a and 10b of the plate assembly 10 comprises at least one corrugation 14c formed on the third planar portion 12c to define the first flow passage 12. The at least one corrugation 14c serves different functions. For example, the at least one corrugation 14c is adapted to direct fluid flow along the distribution plate 10c, limit first fluid flow to the first and the second peripheral walls 14a and 14b and facilitate forming of secure joints between the first plate 10a and the second plate 10b. The distribution plate 10c is formed with a first set of openings 16c and a second set of openings 18c. The first set of openings 16c are aligned with respect to the first set of apertures 16a and the first set of holes 16b formed on the first plate 10a and the second plate 10b respectively to configure a first manifold 20. Similarly, the second set of openings 18c are aligned with respect to the second set of apertures 18a and the second set of holes 18b formed on the first plate 10a and the second plate 10b respectively to configure a second manifold 30.

[0033] The strategically arranged corrugations 14c along the distribution plate 10c, particularly, along third planar portion 12c of the distribution plate 10c define four passes R1, R2, R3 and R4 along the distribution plate 10c. FIG. 5 illustrates a top view of the distribution plate 10c depicting the four passes R1, R2, R3 and R4 of a refrigerant flow along the distribution plate 10c. The strategically arranged corrugations 14c serve additional functions. For example, at least a portion of at least one first corrugation 14c is arranged along the first and the second peripheral walls 14a and 14b of the respective first and the second plate 10a and 10b to limit flow of first fluid to the first and second peripheral walls 14a and 14b respectively. The height "H" of the corrugation 14c is equal to the spacing between the first planar portion 12a and the second planar portion 12b. Such configuration of the corrugation 14c prevent the first fluid from reaching the weaker sections of the core 100a, particularly, sides of the core 100a formed by staggered peripheral walls 14a and 14b. Further, at least a portion of at least one second corrugation 14c provided at central portion of the distribution plate 10c is adapted to define outline for flow of first fluid, particularly, refrigerant along the central portion of the distribution plate 10c. Furthermore, at least a portion of at least one corrugation 14c arranged proximal to at least a portion of at least one opening of the first and the second set of openings 16c and 18c. More specifically, the at least a portion of at least one corrugation 14c arranged proximal to at least a portion of the first set of openings 16c through which the high-pressure first fluid, particularly, the high-pressure refrigerant enters the first flow passages 12. Such strategic arrangement of the corrugations provide sufficient indirect contact between the first plate 10a and the second plate 10b of the plate assembly 10 through the corrugations 14c to configure secure connection between the first plate 10a and the second plate 10b. The corrugations 14c provide sufficient contact between the distribution plate 10c and the first plate 10a and the second plate 10b to configure secure joint between the first plate 10a and the second plate 10b, thereby enabling the chiller 100 to withstand high-pressure of the refrigerant flowing through the first flow passages 12. The secure connection between the first plate 10a and the second plate 10b of the plate assembly 10 enables the plate assembly 10 to withstand high pressures of the refrigerant flowing in the first fluid passage 12 configured between the first plate 10a and the second plate 10b. More specifically, the secure connection between the first plate 10a and the second plate 10b prevents separation of the first plate 10a from the second plate 10b due to high pressure refrigerant flowing between the first and second plates 10a and 10b.

[0034] Further, the distribution plate 10c comprises at least one additional protruding features 19c formed on the planar portion 12c thereof and adapted to provide sufficient contact between the distribution plate 10c and the first plate 10a and the second plate 10b to configure secure joint there-between. The at least one protruding features 19c are adapted to extend either towards the first plate 10a or towards the second plate 10b. More specifically, the additional protruding features 19c provide sufficient indirect contact between the first plate 10a and the second plate 10b through additional protruding features 19c to configure secure connection between the first plate 10a and the second plate 10b. Furthermore, the corrugations 14c configures micro-channels for flow of first fluid, particularly, the high-pressure refrigerant along the distribution plate 10c. Such configuration of the plate assembly 10 with strategically arranged corrugations 14c and the additional protruding features 19c formed on the distribution plate 10c and the first flow passage 12 sandwiched between the first plate 10a and 10b is a capable of withstanding high pressures of refrigerant flowing through the flow passage 12.

[0035] FIG. 6 illustrates perspective view of the chiller 100. FIG. 7 illustrates a side view of the chiller 100 in accordance with an embodiment of the present invention. The chiller 100 is for heat exchange between the first fluid, particularly, a refrigerant and the second fluid, particularly, a coolant. The chiller 100 comprises a plurality of plate assemblies 10 as explained above, a first set of inlet and outlet ports 20a and 20b and a second set inlet and outlet ports 30a and 30b.

[0036] The plate assemblies 10 are stacked with respect to each other to configure the core 100a of the chiller 100. Each plate assembly 10 is adapted to define first flow passages 12 between the first and the second plates 10a and 10b thereof. Further, each plate assembly 10 is adapted to define second flow passages 22 with adjacent fluid assemblies 10 on opposite sides thereof. More specifically, referring to the FIG. 8 depicting enlarged view of the sectional view of the chiller 100 along section view A-A' of FIG. 7, the plate assembly 10 is adapted to configure second flow passage 22 between the first plate 10a thereof and a second plate 10b of a first adjacent plate assembly 10. Further, the plate assembly 10 adapted to configure second flow passage 22 between the second plate 10b thereof and a first plate 10a of a second adjacent plate assembly 10 opposite to the first adjacent plate assembly 10. With such arrangement, the first flow passages 12 formed between first and second plates 10a and 10b of the plate assembles 10 are sandwiched between adjacent second flow passages 22 formed between the adjacent plate assemblies 10. With such arrangement of the distribution plate 10c between the first and second plates 10a and 10b, the first flow passages 12 and second flow passages 22 are formed adjacent to each other for efficient heat transfer between fluids flowing through the first flow passages 12 and the second flow passages 22. In accordance with an embodiment of the present invention, the first fluid passages 12 are for refrigerant flow while the second flow passages 22 are for coolant flow.

[0037] The multiple first flow passages 12 corresponding to the multiple plate assemblies 10 being in fluid communication with a first manifold 20 is illustrated in FIG.9. The first manifold 20 is formed by aligning and engaging the first set of openings 16c formed on the distribution plates 10c of the corresponding plate assemblies 10 configuring the core 100a. The first set of inlet and outlet ports 20a and 20b being in fluid communication with the first manifold 20 for ingress and egress of first fluid with respect to the first flow passages 12 configured between first and second plates 10a and 10b of the plate assemblies 10 is also depicted in FIG. 9.

[0038] Similarly, the second flow passages 22 corresponding to the multiple plate assemblies 10 being in fluid communication with a second manifold 30 is illustrated in FIG. 10. The second manifold 30 is formed by the aligning and engaging the second set of apertures 18a and a s set of holes 18b formed on the respective first plates 10a and the second plates 10b of the corresponding plate assemblies 10 configuring the core 100a. Further, the second set of inlet and outlet ports 30a and 30b being in fluid communication with the second manifold 30 for ingress and egress of second fluid with respect to the second flow passages 21 configured between adjacent plate assemblies 10 of the chiller 100 is depicted in the FIG. 10. The second set of apertures 18a, the second set of holes 18b, the second set of openings 18c and the second set of inlet and outlet ports 30a and 30b are comparatively larger than the corresponding first set of apertures 16a, the first set of holes 16b, the first set of openings 16c and the first set of inlet and outlet ports 20a and 20b considering that the first set of apertures 16a and the first set of inlet and outlet ports 20a and 20b handle refrigerant in gaseous phase.

[0039] Furthermore, the chiller 100 comprises a plurality of turbulators 40 arranged between adjacent plate assemblies 10 and adapted retard flow through second flow passages 22. FIG. 11 illustrates the turbulator 40. In accordance with an embodiment, each of the turbulators 40 comprises a first portion 46a and second portion 46b disposed on opposites sides of the rib 19a formed on the first plate 10a. Each turbulator 40 further comprises a first set of holes 42a and a second set of holes 42b aligned with a first set of apertures 16a and a second set of apertures 18a formed on the first plate 10a. The turbulators 40 are disposed within the second flow passages 22 configured between the adjacent plate assemblies 10 to retard the flow in the second flow passages 22. Accordingly, the turbulators 20 improve heat exchange between the first fluid, particularly refrigerant flowing through first flow passages 12 and the second fluid, particularly, coolant flowing through the second flow passages 22.

[0040] Still further, the chiller 100 comprises a pair of top and bottom plates 50a and 50b and an additional pair of reinforcement plates 60a and 60b each formed with holes. The first set of inlet and outlet ports 20a and 20b are aligned with the corresponding holes formed on the top and bottom plates 50a and 50b and the additional pair of reinforcement plates 60a and 60b. Similarly, the second set of inlet and outlet ports 30a and 30b are aligned with the corresponding holes formed on the top and bottom plates 50a and 50b and the additional pair of reinforcement plates 60a and 60b. The chiller 100 includes sealing elements disposed between the first set of inlet and outlet ports 20a and 20b and the top plate 50a to prevent leakage from the chiller 100. Further, the chiller 100 includes sealing elements disposed between the second set of inlet and outlet ports 30a and 30b and the top plate 50a to prevent leakage from the chiller 100. The plate assemblies 10 stacked together to configure the core 100a are arranged and held between the top and bottom plates 50a and 50b and are joined together by brazing. The top and bottom plates 60a and 60b are arranged between the pair of reinforcement plates 50a and 50b and joined together by brazing. The plate assemblies 10 configuring the core 100a are held between the pair of top and bottom plates 50a and 50b and an additional pair of reinforcement plates 60a and 60b. More specifically, the top plate 50a and the bottom plate 50b securely holds together the stacked plate assemblies 10 forming the core of the chiller 100. Further reinforcement plates 60a and 60b securely holds the stacked plate assemblies 10 together with the top and bottom plates 50a and 50b. However, the sidewall of the core of the chiller 100 remains unreinforced and remains weak due to staggered configuration of the peripheral walls 14a and 14b of the first and second plates 10a and 10b of the adjacent plate assemblies 10.

[0041] All the above-described embodiments are just to explain the present invention while more embodiments and combinations thereof might exist. Hence, the present invention should not be limited to the above-described embodiments aloneLIST OF REFERENCE NUMERALS

[0042] ReferenceDescription100heat exchanger, particularly, a chiller100aheat exchanger core10a plate assembly10afirst plate12first flow passages22second flow passages12afirst planar portion of the first plate14aperipheral wall of the first plate16afirst set of apertures18asecond set of apertures10bsecond plate12bsecond planar portion of the second plate14bperipheral wall of the second plate16bfirst set of holes16bfirst set of holes18bsecond set of holes10cdistribution plate12cthird planar portion14ccorrugations16cfirst set of openings18csecond set of openings19arib on the first plate19brib on the second plate19cprotruding feature on the distribution plate20first manifold20afirst inlet port20bfirst outlet port30second manifold30asecond inlet port30bsecond outlet port50atop plate50bbottom plate60afirst reinforcement plate60bsecond reinforcement plate40turbulatorsR1first pass of first fluid, particularly, refrigerant definedR2second pass of refrigerantR3third pass of refrigerantR4fourth pass of refrigerantGgap between innermost corrugations defining u-flow between second and third pass of refrigerant flow along distribution plate

Examples

Embodiment Construction

[0024]It must be noted that the figures disclose the invention in a detailed enough way to be implemented, the figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0025]In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements that are similar but not identical. No idea of priority should be inferred from such indexation, as these may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

[0026]The present is explained with example of a chiller, wherein the chiller comprises multiple plate assemblies stacked with respect to one another. Each of the plate assemblies comprises a distribution plate sandwiched between a first plate ...

TECHNICAL FIELD

[0001] The present invention relates to a heat exchanger, more particularly, the present invention relates to a plate type heat exchanger for use in a vehicle.BACKGROUND

[0002] A vehicle generally includes various heat exchangers such as for example, a radiator, a condenser, an evaporator and a charged air cooler. With technological shift from conventional internal combustion engine driven vehicles to electric vehicles, there is a need for battery cooling and dedicated heat exchangers for battery cooling such as for example a chiller. The chiller is for supplying cooled coolant to a battery-cooling module that in turn extracts thermal energy from the batteries by being in contact with the batteries. Generally, the chiller is a plate type heat exchanger. The plate type heat exchangers provide several advantages compared to conventional tube type heat exchangers. For example, the plate type heat exchangers are compact, space efficient, exhibit enhanced heat transfer efficiency compared to tube type heat exchangers. Further, the plate type heat exchangers are cost effective and environment friendly compared to the tube type heat exchangers. Further, the plates of the plate type heat exchangers are formed by easy, repeatable, and cost effective stamping process. The plate type heat exchangers offer high exchange area for heat exchange fluids. The plate type heat exchangers can be formed of recyclable aluminum material and can be formed from single material instead different parts of different materials. The plate type heat exchangers have robust construction and withstand high pressures due to the plates being connected at multiple points. However, there are challenges associated with use of plate type heat exchangers.

[0003] The plate type heat exchanger includes multiple plates, a first set of inlet and outlet ports and a second set of inlet and outlet ports. The plate type heat exchanger optionally includes multiple turbulators. The multiple plates are stacked with respect to each other and joined to each other to define first flow passages and second flow passages adjacent to the first fluid flow passages for heat exchange between first and second fluid flowing through the first and second flow passages. In case the heat exchanger is a chiller, the first flow passages are for refrigerant flow and the second flow passages are for coolant flow. Each plate comprises a first set of apertures and a second set of apertures. The first set of apertures configure the first set of channels in fluid communication with first flow passages and the second set of apertures configure the second set of channels in fluid communication with second flow passages. The first set of inlet and outlet ports are for ingress and egress of first fluid with respect to the first flow passages. The second set of inlet and outlet ports are for ingress and egress of second fluid with respect to the second flow passages.

[0004] With increasing environmental concern, environmentally friendly refrigerants such as R744 are preferred over other synthetic refrigerants, particularly, Hydro-fluoro-olefin based refrigerants such as R1234yf. The use of R744 in vehicle air conditioning system exhibits several advantages such as non-toxicity, non-flammability, and inexpensive. However, the use of carbon dioxide as refrigerant face several challenges. Particularly, the elements, such as compressor and heat exchangers, such as for example, chiller interacting with the high-pressure carbon dioxide as refrigerant should be capable of withstanding the high pressures. Since the chiller is formed by joining plates, wherein adjacent plates are joined to create refrigerant flow passages there-between, there are chances of refrigerant leakage due to mechanical failures such as cracks and adjacent plates separating from each, particularly, at weaker sections, where the connection between the plates is weak and when subjected to high pressures. Further, the conventional chiller face challenges in directing the flow along the plates to achieve controlled refrigerant flow to achieve high efficiency and performance. Further, the conventional plate type heat exchangers, chiller fails under salt spray / corrosion testing.

[0005] Accordingly, there is a need for a plate type heat exchanger, particularly, a chiller formed by joining multiple plates, wherein adjacent plates can be securely joined to each other to configure refrigerant flow passages there between. The joints between the adjacent plates, particularly, the large unsupported areas between the adjacent plates act as weak points that are prone to mechanical failures. Particularly, there is a need for chiller formed by joining multiple plates, wherein the adjacent plates configuring fluid flow passages are securely held together to withstand high pressure exerted by high pressure refrigerant flowing between the adjacent plates configuring refrigerant flow passages. Further, there is a need for a plate type heat exchanger, wherein the plates configuring the plate type heat exchanger are capable of directing high-pressure refrigerant away from weaker sections of the heat exchanger, thereby improving durability and service life of the plate heat exchanger. Furthermore, there is a need for a plate type heat exchanger, wherein the plates configuring the plate type heat exchanger control refrigerant flow along the plates to for improved heat exchanger to achieve high efficiency and performance of the plate type heat exchanger. Furthermore, there is a need for a plate type heat exchanger with such arrangement of plates that renders it challenging for corrosion to penetrate through sidewalls and damage the plate heat exchanger, thereby enabling the plate type heat exchanger to pass the corrosion test.SUMMARY

[0006] A plate assembly for a heat exchanger is disclosed in accordance with an embodiment of the present invention. The plate assembly comprises a first plate, a second plate and a distribution plate. The first plate comprises a first planar portion and a first peripheral wall. The second plate comprises a second planar portion and a second peripheral wall. The second planar portion is adapted to be arranged spaced from the first planar portion. The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate adapted to define first flow passage between the first and second planar portions. The first and the second peripheral walls adapted to interact with each other to maintain the first and the second planar portions spaced from each other to receive the distribution plate between the first and second plate. The distribution plate comprises at least one corrugation formed on the third planar portion. The at least one corrugation adapted to direct fluid flow along the distribution plate, limit first fluid flow to the first and the second peripheral walls and facilitate forming of secure joints between the first plate and the second plate.

[0007] Generally, the first plate comprises a first set of apertures and a second set of apertures aligned to a first set of holes and a second set of holes formed on the second plate and a first set of openings and a second set of openings formed on the distribution plate to configure a first manifold and a second manifold.

[0008] Particularly, at least a portion of at least one corrugations is arranged proximal to at least a portion of at least one opening of at least one of the first set of openings and the second set of openings.

[0009] In accordance with an embodiment of the present invention, outer sides of the first peripheral wall fits within inner sides of the second peripheral wall at a distance from the base of the second peripheral wall.

[0010] Specifically, at least one first corrugation is arranged along the first and the second peripheral walls of the respective first and the second plate to limit flow of first fluid to the first and second peripheral walls.

[0011] Further, at least one second corrugation provided at central portion of the distribution plate is adapted to define outline for flow of first fluid along the central portion of the distribution plate.

[0012] Particularly, the corrugations define four passes along the distribution plate.

[0013] More specifically, the corrugations configures micro-channels for flow of first fluid along the distribution plate.

[0014] Further, the distribution plate comprises additional protruding features formed on the planar portion thereof and adapted to provide sufficient contact between the distribution plate and at least one of the first plate and the second plate to configure secure joint there between.

[0015] Generally, at least one of the first plate and the second plate comprises a corresponding rib extending along at least a portion of the length of the plate and adapted to define u-flow along the plate.

[0016] Specifically, the rib emanates from a portion of the first peripheral wall proximal to the first set of apertures and terminates before another portion of the first peripheral wall proximal to the second set of apertures to configure u-flow of second fluid along the first plate.

[0017] More specifically, the rib is adapted to prevent flow through the gap "G" between the innermost corrugations defining the u-flow between the second pass R2 and the third pass R3 of the first fluid along the distribution plate.

[0018] Also is disclosed a heat exchanger in accordance with an embodiment of the present invention. The heat exchanger is for heat exchange between a first fluid and a second fluid and comprises a plurality of plate assemblies, a first set of inlet and outlet ports and a second set inlet and outlet ports. The plate assemblies are stacked with respect to each other to configure a core of the heat exchanger. Each plate assembly being as disclosed above and adapted to define first flow passages between the first and the second plates thereof. Further, each plate assembly adapted to define second flow passages with adjacent fluid assemblies on opposite sides thereof. The first flow passages corresponding to the multiple plate assemblies being in fluid communication with a first manifold. Similarly, the second flow passages corresponding to the multiple plate assemblies being in fluid communication with a second manifold. The first set of inlet and outlet ports being in fluid communication with a first manifold for ingress and egress of first fluid with respect to the first flow passages configured within the heat exchanger. Similarly, the second set inlet and outlet ports being in fluid communication with a second manifold for ingress and egress of second fluid with respect to the second flow passages configured within the heat exchanger.

[0019] In accordance with an embodiment of the present invention, the first manifold is formed by aligned and engaging second set of openings formed on the distribution plates of the corresponding plate assemblies. The second manifold is formed by the aligned and engaging first set of apertures and a first set of holes formed on the respective first plates and the second plates of the corresponding plate assemblies configuring the core.

[0020] More specifically, the plate assembly is adapted to configure second flow passage between the first plate thereof and a second plate of a first adjacent plate assembly. Further, the plate assembly adapted to configure second flow passage between the second plate thereof and a first plate of a second adjacent plate assembly opposite to the first adjacent plate assembly.

[0021] Furthermore, the heat exchanger comprises a plurality of turbulators arranged between adjacent plate assemblies and adapted retard flow through second flow passages. The turbulators comprising a first set of holes and a second set of holes ) aligned with a first set of apertures and a second set of apertures formed on the first plate.

[0022] Still further, the heat exchanger comprises a pair of top and bottom plates and an additional pair of reinforcement plates. The plate assemblies configuring the core are arranged between the top and bottom plates. The top and bottom plates are arranged between the pair of reinforcement plates.BRIEF DESCRIPTION

[0023] Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained, as the same becomes better understood by reference to the following description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates an exploded view of a plate assembly in accordance with an embodiment of the present invention; FIG. 2 illustrates a perspective view of a first plate of the plate assembly of FIG. 1; FIG. 3 illustrates a perspective view of a second plate of the plate assembly of FIG. 1; FIG. 4 illustrates a perspective view of a distribution plate of the plate assembly of FIG. 1; FIG. 5 illustrates a top view of the distribution plate of FIG. 4 depicting four passes of a refrigerant flow along the distribution plate. FIG. 6 illustrates a perspective view of a heat exchanger, particularly, a chiller in accordance with an embodiment of the present invention. FIG. 7 illustrates a side view of the chiller of FIG. 6. FIG. 8 illustrates a sectional view of the chiller along section line A-A' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line A-A'. FIG. 9 illustrates a sectional view of the chiller along section line B-B' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line B-B'. FIG. 10 illustrates a sectional view of the chiller along section line C-C' of FIG. 7, also is depicted an enlarged view of the sectional view of the chiller along the section line C-C'. FIG. 11 illustrates a perspective view of the turbulators arranged between adjacent plate assemblies configuring the chiller of FIG.6. DETAILED DESCRIPTION

[0024] It must be noted that the figures disclose the invention in a detailed enough way to be implemented, the figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0025] In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements that are similar but not identical. No idea of priority should be inferred from such indexation, as these may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

[0026] The present is explained with example of a chiller, wherein the chiller comprises multiple plate assemblies stacked with respect to one another. Each of the plate assemblies comprises a distribution plate sandwiched between a first plate and a second plate. The first plate comprises a first planar portion and a first peripheral wall. The second plate comprises a second planar portion and a second peripheral wall. The second planar portion is adapted to be arranged spaced from the first planar portion. The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate adapted to define first flow passage between the first and second planar portions. The first and the second peripheral walls are adapted to interact with each other to maintain the first and the second planar portions spaced from each other to receive the distribution plate between the first and second plate. The distribution plate comprises at least one corrugation formed on the third planar portion. The at least one corrugation adapted to direct fluid flow along the distribution plate, limit first fluid flow to the first and the second peripheral walls and facilitate forming of secure joints between the first plate and the second plate. The plate assembly is adapted to configure second flow passages with adjacent plate assemblies. With such configuration, the first flow passage for refrigerant flow is arranged between second flow passages for coolant flow to configure heat exchange between refrigerant and coolant.

[0027] However, the present invention is also applicable to any heat exchanger used in vehicular or non-vehicular environment, wherein it is required to configure secure brazing connection between distribution plate and the first and second plates configuring the plate assembly forming the heat exchanger and wherein it is required to limit fluid flow to weaker sections of the heat exchanger. The weaker sections of the heat exchanger could be for example the sides of the heat exchanger formed by staking together the peripheral walls of the first and second plates. Further, the present invention is also applicable wherein high-pressure fluid is introduced between plates configuring the heat exchanger and the plates are required to be securely joined to each other to withstand high pressure of the fluid flowing between the plates.

[0028] The present disclosure envisages a heat exchanger, particularly, a chiller 100 formed by assembling a plurality of plate assemblies 10. FIG. 1 illustrates an exploded view of a plate assembly 10 in accordance with an embodiment of the present invention. The plate assembly 10 includes a first plate 10a, a second plate 10b and a distribution plate 10c. The distribution plate 10c is arranged between the first plate 10a and the second plate 10b.

[0029] FIG. 2 illustrates a perspective view of the first plate 10a. The first plate 10a comprises a first planar portion 12a and a first peripheral wall 14a. The first peripheral wall 14a extending along the periphery of the first planar portion 12a is either orthogonally extending or inclined with respect to the first planar portions 12a. The first plate 10a comprises a first set of apertures 16a and a second set of apertures 18a formed along opposite lateral sides thereof.

[0030] FIG. 3 illustrates a perspective view of the second plate 10b. The second plate 10b comprises a second planar portion 12b and a second peripheral wall 14b. The second planar portion 12b is adapted to be arranged spaced from the first planar portion 12a. The second peripheral wall 14b extending along the periphery of the second planar portion 12b. The second peripheral wall 14b is either orthogonally extending or inclined with respect to the second planar portion 12b. The first and the second peripheral walls 14a and 14b are adapted to interact with each other to maintain the first and the second planar portions spaced from each other. In accordance with an embodiment of the present invention as illustrated in enlarged sectional view of the heat exchanger depicted in FIG. 8, outer sides of the first peripheral wall 14a fits within inner sides of the second peripheral wall 14b at a distance from the base of the second peripheral wall 14b. Such arrangement of the first peripheral wall 14a interacting with the second peripheral wall 14b maintains the first planar portion 12a and the second planar portion 12b spaced apart from each other. The stacked peripheral walls 14a and 14b of the first and second plates 10a and 10b define the sidewalls of a core 100a of the chiller 100. Due to such configuration of the sidewalls of the chiller 100 formed by staggered peripheral walls 14a and 14b, the sides of the chiller are comparatively weaker than top and bottom sides of the chiller 100.

[0031] The second plate 10b comprises a first set of holes 16b and a second set of holes 18b formed along opposite lateral sides of the second plate 10b. Generally, at least one of the first plate 10a and the second plate 10b comprises a corresponding rib 19a, 19b extending along at least a portion of the length of the plate 10a, 10b and adapted to define u-flow along the plate 10a, 10b. Specifically, the rib 19a emanates from a portion of the first peripheral wall 14a proximal to the second set of apertures 18a and terminates before another portion of the first peripheral wall 14a proximal to the first set of apertures 16a to configure u-flow of second fluid, particularly, coolant along the first plate 10a. More specifically, the rib 19a is adapted to prevent flow through the gap "G" between the innermost corrugations 14c defining the u-flow between the second pass R2 and the third pass R3 of the first fluid along the distribution plate 10c.

[0032] FIG. 4 illustrates a perspective view of the distribution plate 10c. The distribution plate 10c comprises a third planar portion 12c arranged between the first planar portion 12a and the second planar portion 12b of the plate assembly 10. The distribution plate 10c is adapted to define first flow passage 12 between the first planar portion 12a and the second planar portion 12b. The distribution plate 10c is arranged between the first plate 10a and the second plate 10b to define the first flow passages 12 between the distribution plate 10c and the respective first and second plates 10a and 10b. Specifically, the distribution plate 12c received between spaced apart first planar portion 12a and the second planar portion 12b of the first and the second plate 10a and 10b of the plate assembly 10 comprises at least one corrugation 14c formed on the third planar portion 12c to define the first flow passage 12. The at least one corrugation 14c serves different functions. For example, the at least one corrugation 14c is adapted to direct fluid flow along the distribution plate 10c, limit first fluid flow to the first and the second peripheral walls 14a and 14b and facilitate forming of secure joints between the first plate 10a and the second plate 10b. The distribution plate 10c is formed with a first set of openings 16c and a second set of openings 18c. The first set of openings 16c are aligned with respect to the first set of apertures 16a and the first set of holes 16b formed on the first plate 10a and the second plate 10b respectively to configure a first manifold 20. Similarly, the second set of openings 18c are aligned with respect to the second set of apertures 18a and the second set of holes 18b formed on the first plate 10a and the second plate 10b respectively to configure a second manifold 30.

[0033] The strategically arranged corrugations 14c along the distribution plate 10c, particularly, along third planar portion 12c of the distribution plate 10c define four passes R1, R2, R3 and R4 along the distribution plate 10c. FIG. 5 illustrates a top view of the distribution plate 10c depicting the four passes R1, R2, R3 and R4 of a refrigerant flow along the distribution plate 10c. The strategically arranged corrugations 14c serve additional functions. For example, at least a portion of at least one first corrugation 14c is arranged along the first and the second peripheral walls 14a and 14b of the respective first and the second plate 10a and 10b to limit flow of first fluid to the first and second peripheral walls 14a and 14b respectively. The height "H" of the corrugation 14c is equal to the spacing between the first planar portion 12a and the second planar portion 12b. Such configuration of the corrugation 14c prevent the first fluid from reaching the weaker sections of the core 100a, particularly, sides of the core 100a formed by staggered peripheral walls 14a and 14b. Further, at least a portion of at least one second corrugation 14c provided at central portion of the distribution plate 10c is adapted to define outline for flow of first fluid, particularly, refrigerant along the central portion of the distribution plate 10c. Furthermore, at least a portion of at least one corrugation 14c arranged proximal to at least a portion of at least one opening of the first and the second set of openings 16c and 18c. More specifically, the at least a portion of at least one corrugation 14c arranged proximal to at least a portion of the first set of openings 16c through which the high-pressure first fluid, particularly, the high-pressure refrigerant enters the first flow passages 12. Such strategic arrangement of the corrugations provide sufficient indirect contact between the first plate 10a and the second plate 10b of the plate assembly 10 through the corrugations 14c to configure secure connection between the first plate 10a and the second plate 10b. The corrugations 14c provide sufficient contact between the distribution plate 10c and the first plate 10a and the second plate 10b to configure secure joint between the first plate 10a and the second plate 10b, thereby enabling the chiller 100 to withstand high-pressure of the refrigerant flowing through the first flow passages 12. The secure connection between the first plate 10a and the second plate 10b of the plate assembly 10 enables the plate assembly 10 to withstand high pressures of the refrigerant flowing in the first fluid passage 12 configured between the first plate 10a and the second plate 10b. More specifically, the secure connection between the first plate 10a and the second plate 10b prevents separation of the first plate 10a from the second plate 10b due to high pressure refrigerant flowing between the first and second plates 10a and 10b.

[0034] Further, the distribution plate 10c comprises at least one additional protruding features 19c formed on the planar portion 12c thereof and adapted to provide sufficient contact between the distribution plate 10c and the first plate 10a and the second plate 10b to configure secure joint there-between. The at least one protruding features 19c are adapted to extend either towards the first plate 10a or towards the second plate 10b. More specifically, the additional protruding features 19c provide sufficient indirect contact between the first plate 10a and the second plate 10b through additional protruding features 19c to configure secure connection between the first plate 10a and the second plate 10b. Furthermore, the corrugations 14c configures micro-channels for flow of first fluid, particularly, the high-pressure refrigerant along the distribution plate 10c. Such configuration of the plate assembly 10 with strategically arranged corrugations 14c and the additional protruding features 19c formed on the distribution plate 10c and the first flow passage 12 sandwiched between the first plate 10a and 10b is a capable of withstanding high pressures of refrigerant flowing through the flow passage 12.

[0035] FIG. 6 illustrates perspective view of the chiller 100. FIG. 7 illustrates a side view of the chiller 100 in accordance with an embodiment of the present invention. The chiller 100 is for heat exchange between the first fluid, particularly, a refrigerant and the second fluid, particularly, a coolant. The chiller 100 comprises a plurality of plate assemblies 10 as explained above, a first set of inlet and outlet ports 20a and 20b and a second set inlet and outlet ports 30a and 30b.

[0036] The plate assemblies 10 are stacked with respect to each other to configure the core 100a of the chiller 100. Each plate assembly 10 is adapted to define first flow passages 12 between the first and the second plates 10a and 10b thereof. Further, each plate assembly 10 is adapted to define second flow passages 22 with adjacent fluid assemblies 10 on opposite sides thereof. More specifically, referring to the FIG. 8 depicting enlarged view of the sectional view of the chiller 100 along section view A-A' of FIG. 7, the plate assembly 10 is adapted to configure second flow passage 22 between the first plate 10a thereof and a second plate 10b of a first adjacent plate assembly 10. Further, the plate assembly 10 adapted to configure second flow passage 22 between the second plate 10b thereof and a first plate 10a of a second adjacent plate assembly 10 opposite to the first adjacent plate assembly 10. With such arrangement, the first flow passages 12 formed between first and second plates 10a and 10b of the plate assembles 10 are sandwiched between adjacent second flow passages 22 formed between the adjacent plate assemblies 10. With such arrangement of the distribution plate 10c between the first and second plates 10a and 10b, the first flow passages 12 and second flow passages 22 are formed adjacent to each other for efficient heat transfer between fluids flowing through the first flow passages 12 and the second flow passages 22. In accordance with an embodiment of the present invention, the first fluid passages 12 are for refrigerant flow while the second flow passages 22 are for coolant flow.

[0037] The multiple first flow passages 12 corresponding to the multiple plate assemblies 10 being in fluid communication with a first manifold 20 is illustrated in FIG.9. The first manifold 20 is formed by aligning and engaging the first set of openings 16c formed on the distribution plates 10c of the corresponding plate assemblies 10 configuring the core 100a. The first set of inlet and outlet ports 20a and 20b being in fluid communication with the first manifold 20 for ingress and egress of first fluid with respect to the first flow passages 12 configured between first and second plates 10a and 10b of the plate assemblies 10 is also depicted in FIG. 9.

[0038] Similarly, the second flow passages 22 corresponding to the multiple plate assemblies 10 being in fluid communication with a second manifold 30 is illustrated in FIG. 10. The second manifold 30 is formed by the aligning and engaging the second set of apertures 18a and a s set of holes 18b formed on the respective first plates 10a and the second plates 10b of the corresponding plate assemblies 10 configuring the core 100a. Further, the second set of inlet and outlet ports 30a and 30b being in fluid communication with the second manifold 30 for ingress and egress of second fluid with respect to the second flow passages 21 configured between adjacent plate assemblies 10 of the chiller 100 is depicted in the FIG. 10. The second set of apertures 18a, the second set of holes 18b, the second set of openings 18c and the second set of inlet and outlet ports 30a and 30b are comparatively larger than the corresponding first set of apertures 16a, the first set of holes 16b, the first set of openings 16c and the first set of inlet and outlet ports 20a and 20b considering that the first set of apertures 16a and the first set of inlet and outlet ports 20a and 20b handle refrigerant in gaseous phase.

[0039] Furthermore, the chiller 100 comprises a plurality of turbulators 40 arranged between adjacent plate assemblies 10 and adapted retard flow through second flow passages 22. FIG. 11 illustrates the turbulator 40. In accordance with an embodiment, each of the turbulators 40 comprises a first portion 46a and second portion 46b disposed on opposites sides of the rib 19a formed on the first plate 10a. Each turbulator 40 further comprises a first set of holes 42a and a second set of holes 42b aligned with a first set of apertures 16a and a second set of apertures 18a formed on the first plate 10a. The turbulators 40 are disposed within the second flow passages 22 configured between the adjacent plate assemblies 10 to retard the flow in the second flow passages 22. Accordingly, the turbulators 20 improve heat exchange between the first fluid, particularly refrigerant flowing through first flow passages 12 and the second fluid, particularly, coolant flowing through the second flow passages 22.

[0040] Still further, the chiller 100 comprises a pair of top and bottom plates 50a and 50b and an additional pair of reinforcement plates 60a and 60b each formed with holes. The first set of inlet and outlet ports 20a and 20b are aligned with the corresponding holes formed on the top and bottom plates 50a and 50b and the additional pair of reinforcement plates 60a and 60b. Similarly, the second set of inlet and outlet ports 30a and 30b are aligned with the corresponding holes formed on the top and bottom plates 50a and 50b and the additional pair of reinforcement plates 60a and 60b. The chiller 100 includes sealing elements disposed between the first set of inlet and outlet ports 20a and 20b and the top plate 50a to prevent leakage from the chiller 100. Further, the chiller 100 includes sealing elements disposed between the second set of inlet and outlet ports 30a and 30b and the top plate 50a to prevent leakage from the chiller 100. The plate assemblies 10 stacked together to configure the core 100a are arranged and held between the top and bottom plates 50a and 50b and are joined together by brazing. The top and bottom plates 60a and 60b are arranged between the pair of reinforcement plates 50a and 50b and joined together by brazing. The plate assemblies 10 configuring the core 100a are held between the pair of top and bottom plates 50a and 50b and an additional pair of reinforcement plates 60a and 60b. More specifically, the top plate 50a and the bottom plate 50b securely holds together the stacked plate assemblies 10 forming the core of the chiller 100. Further reinforcement plates 60a and 60b securely holds the stacked plate assemblies 10 together with the top and bottom plates 50a and 50b. However, the sidewall of the core of the chiller 100 remains unreinforced and remains weak due to staggered configuration of the peripheral walls 14a and 14b of the first and second plates 10a and 10b of the adjacent plate assemblies 10.

[0041] All the above-described embodiments are just to explain the present invention while more embodiments and combinations thereof might exist. Hence, the present invention should not be limited to the above-described embodiments aloneLIST OF REFERENCE NUMERALS

[0042] ReferenceDescription100heat exchanger, particularly, a chiller100aheat exchanger core10a plate assembly10afirst plate12first flow passages22second flow passages12afirst planar portion of the first plate14aperipheral wall of the first plate16afirst set of apertures18asecond set of apertures10bsecond plate12bsecond planar portion of the second plate14bperipheral wall of the second plate16bfirst set of holes16bfirst set of holes18bsecond set of holes10cdistribution plate12cthird planar portion14ccorrugations16cfirst set of openings18csecond set of openings19arib on the first plate19brib on the second plate19cprotruding feature on the distribution plate20first manifold20afirst inlet port20bfirst outlet port30second manifold30asecond inlet port30bsecond outlet port50atop plate50bbottom plate60afirst reinforcement plate60bsecond reinforcement plate40turbulatorsR1first pass of first fluid, particularly, refrigerant definedR2second pass of refrigerantR3third pass of refrigerantR4fourth pass of refrigerantGgap between innermost corrugations defining u-flow between second and third pass of refrigerant flow along distribution plate

Examples

Embodiment Construction

[0024]It must be noted that the figures disclose the invention in a detailed enough way to be implemented, the figures helping to better define the invention, if need be. The invention should however not be limited to the embodiments disclosed in the description.

[0025]In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements that are similar but not identical. No idea of priority should be inferred from such indexation, as these may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

[0026]The present is explained with example of a chiller, wherein the chiller comprises multiple plate assemblies stacked with respect to one another. Each of the plate assemblies comprises a distribution plate sandwiched between a first plate ...

Claims

1. A plate assembly (10) for a heat exchanger (100), the plate assembly (10) comprising: • a first plate (10a) comprising a first planar portion (12a) and a first peripheral wall (14a); • a second plate (10b) comprising a second planar portion (12b) and a second peripheral wall (14b), the second planar portion (12b) adapted to be arranged spaced from the first planar portion (12a); • a distribution plate (10c) comprising a third planar portion (12c) arranged between the first planar portion (12a) and the second planar portion (12b), the distribution plate (10c) adapted to define first flow passage (12) between the first and second planar portions (12a) and (12b), characterized in that the first and the second peripheral walls (14a) and (14b) are adapted to interact with each other to maintain the first and the second planar portions (12a) and (12b) spaced from each other to receive the distribution plate (10c) between the first and second plate (10a) and (10b), the distribution plate (10c) comprises at least one corrugation (14c) formed on the third planar portion (12c) and adapted to direct fluid flow along the distribution plate (10c), limit first fluid flow to the first and the second peripheral walls (14a) and (14b) and form secure joints between the first plate (10a) and the second plate (10b).

2. The plate assembly (10) as claimed in the previous claim, wherein the first plate (10a) comprises a first set of apertures (16a) and a second set of apertures (18a) aligned to a first set of holes (16b) and a second set of holes (18b) formed on the second plate (10b) and a first set of openings (16c) and a second set of openings (18c) formed on the distribution plate (10c) to configure a first manifold (20) and a second manifold (30).

3. The plate assembly (10) as claimed in the previous claim, wherein at least a portion of at least one corrugation (14c) is arranged proximal to at least a portion of at least one opening of at least one of the first set of openings (16c) and the second set of openings (18c).

4. The plate assembly (10) as claimed in any of the preceding claims, wherein outer sides of the first peripheral wall (14a) fits within inner sides of the second peripheral wall (14b) at a distance from the base of the second peripheral wall (14b).

5. The plate assembly (10) as claimed in any of the preceding claims, wherein at least one first corrugation (14c) arranged along the first and the second peripheral walls (14a) and (14b) of the respective first and the second plate (10a) and (10b) to limit flow of first fluid to the first and second peripheral walls (14a) and (14b).

6. The plate assembly (10) as claimed in any of the preceding claims, wherein at least one second corrugation (14c) provided at central portion of the distribution plate (10c) is adapted to define outline for flow of first fluid along central portion of the distribution plate (10c).

7. The plate assembly (10) as claimed in any of the preceding claims, wherein the corrugations (14c) define four passes along the distribution plate (10c).

8. The plate assembly (10) as claimed in any of the preceding claims, wherein the corrugations (14c) configures micro-channels for flow of first fluid along the distribution plate (10c).

9. The plate assembly (10) as claimed in any of the preceding claims, wherein the distribution plate (10c) further comprises additional protruding features (19c) formed on the planar portion (12c) thereof and adapted to provide sufficient contact between the distribution plate (10c) and at least one of the first plate (10a) and the second plate (10b) to configure secure joint there between.

10. The plate assembly (10)as claimed in any of the preceding claims, wherein at least one of the first plate and the second plate (10a) and (10b) comprises a corresponding rib (19a, 19b) extending along at least a portion of the length of the plate (10a, 10b) and adapted to define u-flow along the plate (10a, 10b).

11. The plate assembly (10) as claimed in the previous claim, wherein the rib (19a) emanates from a portion of the first peripheral wall (14a) proximal to the second set of apertures (18a) and terminates before another portion of the first peripheral wall (14a) proximal to the first set of apertures (16a).

12. The plate assembly (10) as claimed the previous claim, wherein the rib (19a) is adapted to prevent flow through the gap "G" between the innermost corrugations (14c) defining the u-flow between the second pass R2 and the third pass R3 of the first fluid along the distribution plate (10c).

13. A heat exchanger (100) for a heat exchange between a first fluid and at least one second fluid comprising: • a plurality of plate assemblies (10) stacked with respect to each other to configure a core (100a) of the heat exchanger (100), each plate assembly (10) being as claimed in any of the preceding claims adapted to define first flow passages (12) between the first and the second plates (10a) and (10b) thereof, each plate assembly (10) further adapted to define second flow passages (22) with adjacent fluid assemblies (10) on opposite sides thereof, wherein the first flow passages (12) corresponding to the multiple plate assemblies (10) being in fluid communication with a first manifold (20), and wherein the second flow passages (22) corresponding to the multiple plate assemblies (10) being in fluid communication with a second manifold (30), • a first set of inlet and outlet ports (20a) and (20b) being in fluid communication with a first manifold (20) for ingress and egress of first fluid with respect to the first flow passages (12); and • a second set inlet and outlet ports (30a) and (30b) being in fluid communication with a second manifold (30) for ingress and egress of second fluid with respect to the second flow passages (22).

14. The heat exchanger (100) as claimed in the previous claim, wherein the first manifold (20) is formed by aligning and engaging first set of openings (16c) formed on the distribution plates (10c) of the corresponding plate assemblies (10) configuring the core (100a) and the second manifold (30) is formed by the aligning and engaging second set of apertures (18a) and a second set of holes (18b) formed on the respective first plates (10a) and the second plates (10b) of the corresponding plate assemblies (10) configuring the core (100)15. The heat exchanger (100) as claimed in the claim 13, wherein the plate assembly (10) adapted to configure second flow passage (22) between the first plate (10a) thereof and a second plate (10b) of a first adjacent plate assembly (10), the plate assembly (10) further adapted to configure second flow passage (22) between the second plate (10b) thereof and a first plate (10a) of a second adjacent plate assembly (10) opposite to the first adjacent plate assembly (10).

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