A heat exchanger

Abstract

A heat exchanger 100 comprises a core 100a, a first set of inlet and outlet ports 20a and 20b and a second set inlet and outlet ports 30a and 30b. The core 100a comprising a stack of first and second plate assemblies 10 and 11 stacked and fluidically connected to each other to define a height "H" of the core 100a. At least one of a first plate 11a, a second plate 11b and a distribution plate 11c of each second plate assembly 11 comprises an additional aperture 17a, an additional hole 17b and an additional opening 17c respectively aligned to configure an additional channel (33) that forms multiple flow passes along the height "H" of the core 100a. The additional aperture 17a is at least partially disposed between extreme end of a rib 19a and the periphery of a first aperture 16a.

Description

TECHNICAL FIELD

[0001] The present invention relates to a heat exchanger, more particularly, the present invention relates to a plate type chiller for use in an electric 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. The batteries are heated during operation thereof and required to be maintained within a desired temperature range. 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 and space efficient compared to tube type heat exchangers. Further, the plate type heat exchangers are cost effective 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 generally 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 hydrofluoroolefin 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. Although, the pressure drop of the refrigerant increases with the number of passes configured within the heat exchanger core, however, pressure drop for high-pressure refrigerant flowing within the heat exchanger has comparatively less adverse impact on performance of the heat exchanger compared to pressure drop for synthetic refrigerants. Accordingly, more number of refrigerant flow passes can be configured within the heat exchangers using high-pressure refrigerant to improve heat exchange between coolant and high-pressure refrigerant. The more number of passes can be configured by increasing the number of refrigerant flow passes along the plates of the heat exchanger and increasing the number of passes along the height of the heat exchanger core. However, configuring more number of passes of the high-pressure refrigerant along the plates and along height of the heat exchanger core is challenging as distribution of the refrigerant along the plates and different passes along the height of the core is difficult.

[0005] In order to improve the distribution of the refrigerant in the different passes along the plates and different passes along thickness of the heat exchanger core, a combination of first plate assemblies and second plate assemblies are used to configure the heat exchanger core. Each of the first and second plate assemblies comprises multiple plates to configure first flow passage and second flow passages adjacent to first flow passage. The plates of the second plate assemblies comprises an additional aperture in addition to the first set of apertures and second set of apertures formed on the plates of the first plate assemblies. The additional apertures on the plates of the second plate assemblies are aligned to each other to form additional channel. The additional channel in addition to the first and the second set of channels configured by aligning the first and second set of apertures is adapted to improve distribution of the refrigerant along the plates and the different passes along the height of the heat exchanger core. The additional channel inherently obstructs coolant flow in the second flow passages, particularly, the coolant flow passes, thereby creating dead zone and causing pressure drop for coolant flowing in the coolant flow passages. The increased pressure drop of coolant through the coolant flow passages decreases the overall flow of the coolant though the heat exchanger that in turn can adversely impact the performance of the heat exchanger.

[0006] Accordingly, there is a need for a plate type heat exchanger, particularly, a chiller formed by joining multiple plates, wherein the chiller is formed with an additional channel for improving refrigerant distribution in the multiple refrigerant flow passes formed along the plates and along height of the chiller with minimum impact of coolant flow in the second flow passages. Further, there is a need for a heat exchanger, particularly, chiller that is provided with arrangements for preventing pressure drop of coolant flowing through coolant flow passages configured within a heat exchanger, thereby improving efficiency and performance of the heat exchanger. Further, there is a need for a plate type heat exchanger that exhibits improved efficiency and performance.SUMMARY

[0007] A heat exchanger for a heat exchange between a first fluid and a second fluid is disclosed in accordance with an embodiment of the present invention. The heat exchanger comprising a heat exchanger core, a first set of inlet and outlet ports and a second set inlet and outlet ports. The heat exchanger core limited between a distal side and a proximal side and a front side and a rear side. The heat exchanger core comprising a stack of first plate assemblies and a stack of second plate assemblies together defining a height "H" of the heat exchanger core. At least one of the first plate assembly and the second plate assembly comprises at least two of a first plate, a second plate and a distribution plate. At least one of the first plate, the second plate and the distribution plate of each plate assembly comprises at least one of an additional aperture, an additional hole and an additional opening respectively aligned with respect to each other to define an additional channel. The additional channel configures multiple flow passes along the height "H" of the heat exchanger core. The additional aperture is at least partially disposed between extreme end of a rib and a periphery of a first aperture formed on the first plate.

[0008] At least one of the plate assembly comprises at least one of a first plate, a second plate and a distribution plate.

[0009] The first plate comprising a first planar portion and a first peripheral wall. The first planar portion comprises the first set of apertures, a second set of apertures and the rib extending along at least a portion of the length of the first plate. The rib adapted to define u-flow along the first planar portion. The first plate of the second plate assembly further comprising the additional aperture corresponding to the additional opening.

[0010] The second plate comprises the second planar portion and the second peripheral wall. The second planar portion is arranged spaced from the first planar portion and comprising a first set of holes and a second set of holes. The second plate of the second plate assembly further comprises the additional hole corresponding to the additional opening.

[0011] The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate formed with at least one corrugation and comprising a first set of openings and a second set of openings. The distribution plate of the second plate assembly further comprises the additional opening. The first set of openings formed on the distribution plates being aligned with respect to each other to define a first pair of channels, wherein at least one of the distribution plates is without at least one openings to create a barrier within at least one channel.

[0012] The second set of apertures formed on the first plates being aligned with respect to the second set of holes formed on the second plates to define a second pair of channels.

[0013] Generally, each plate assembly adapted to define first flow passage between the first and the second plates thereof. Further, each plate assembly adapted to define second flow passages with adjacent plate assemblies on opposite sides thereof.

[0014] Particularly, at least one of the first pair of channels and the additional channel are adapted to be in fluid communication with the first flow passages and in fluid isolation with the second flow passages defined by the multiple plate assemblies.

[0015] Similarly, the second pair of channels are adapted to be in in fluid communication with the second flow passages and in fluid isolation with the first flow passages defined by the multiple plate assemblies.

[0016] Further, the first set of inlet and outlet ports being in fluid communication with the first pair of channels for ingress and egress of first fluid with respect to the first flow passages. The second set inlet and outlet ports being in fluid communication with the second pair of channels for ingress and egress of second fluid with respect to the second flow passages.

[0017] Specifically, the additional channel is adapted to configure three passes for the first fluid along the height "H" of the heat exchanger core, at least one of the three passes extends along the length of the heat exchanger.

[0018] Generally, the first set of inlet and outlet ports being in the form of openings on a top plate and a top reinforcement plate that receive the heat exchanger core there-between, the first set of inlet and outlet ports are in fluid communication with respective inlet and outlet connector blocks.

[0019] The second set of inlet and outlet ports being in the form of openings on the top plate and the top reinforcement plate are in fluid communication with respective inlet and outlet nozzles.

[0020] Further, the heat exchanger comprises additional port in the form of additional opening on the top plate and the top reinforcement plate. The additional port adapted to configure fluid communication between the additional channel on one side and a connector bore on other side. The connector bore configured within the outlet connector block along distal side of the heat exchanger core.

[0021] Generally, the additional aperture is disposed proximal to the first aperture along the distal side of the heat exchanger core.

[0022] Specifically, the additional aperture is aligned to the first aperture along the distal side of the heat exchanger core.

[0023] More specifically, the additional aperture is disposed between the first aperture and the second aperture along distal side of the heat exchanger core.

[0024] In accordance with an embodiment, the additional aperture is positioned at a distance "S" from the first aperture along the distal side of the heat exchanger core, the distance "S" being in the range of 1.5 to 3 times the diameter "d" of the first aperture.

[0025] Further, the additional aperture is positioned within an angle "α" subtended from center "C" of the first aperture along the distal side of the heat exchanger core, the angle "α" being in the range of 15° to 45°.

[0026] Furthermore, the additional aperture can be of any shape but not limited to circular, elliptical, square and rectangular.

[0027] More specifically, the additional aperture is formed on a raised platform that is offset from the plane of the first planar portion.

[0028] Still further, the additional hole is along the plane of the second planar portion.

[0029] Preferably, the additional opening is at least partially surrounded by at least a portion of at least one corrugation.

[0030] Further, the heat exchanger comprises turbulators disposed between adjacent plate assemblies. Particularly, first set of turbulators are disposed between adjacent first plate assemblies. The second set of turbulators are disposed between adjacent second plate assemblies.

[0031] Particularly, each of the second turbulators comprises additional punched out section in addition to first set of punched out sections and second set of punched out sections corresponding and aligned to the first set of apertures and the second set of apertures respectively.

[0032] More specifically, the additional punched out hole is aligned to the additional aperture.BRIEF DESCRIPTION

[0033] 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 a perspective view of a heat exchanger, particularly, a chiller, in accordance with an embodiment of the present invention. FIG. 2 illustrates a top view of the chiller of the FIG. 1. FIG. 3 illustrates a sectional view of the chiller along sectional plane X-X' of FIG.2, also is illustrated an enlarged view of a top section of the chiller formed by assembling a second set of plate assemblies. FIG. 4 illustrates a side view of the chiller of the FIG. 1. FIG. 5 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line A-A' of FIG. 4. FIG. 6 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line B-B' of FIG. 4. FIG. 7 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line C-C' of FIG. 4. FIG. 8 illustrates an exploded view of a first plate assembly in accordance with an embodiment of the present invention. FIG. 9 illustrates an exploded view of a second plate assembly in accordance with an embodiment of the present invention, wherein each of a first plate, a second plate and distribution plate of the second plate assembly is formed with an additional aperture, hole and opening. FIG. 10 and FIG. 11 depict perspective views of a first plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 12 illustrates top view of the second plate depicting relative position of an additional aperture with respect to a first aperture along distal side of the heat exchanger core FIG. 13 and FIG. 14 depict perspective views of a second plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 15 and FIG. 16 depict perspective views of a distributions plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 17 and FIG. 18 depict top views of the distribution plates of FIG. 15 and FIG. 16 respectively. FIG. 19 depicts a perspective view of a first set of turbulators arranged between adjacent first plate assemblies, wherein exploded view of one such plate assembly is depicted in FIG. 8. FIG. 20 depicts a perspective view of a second set of turbulators arranged between second plate assemblies, wherein exploded view of one such plate assembly is depicted in FIG. 9. DETAILED DESCRIPTION

[0034] 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.

[0035] 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.

[0036] The present invention is explained with example of a chiller, wherein the chiller comprises a stack of first plate assemblies and a stack of second plate assemblies. The stack of second plate assemblies is stacked and fluidically connected to the stack of first plate assemblies to define a height "H" of the chiller core. The second plate assembly comprises at least one of a first plate, a second plate and a distribution plate to define a first fluid flow passage for first fluid, particularly refrigerant between the first and second plates and second fluid flow passages for second fluid, particularly coolant between adjacent second plate assemblies on opposite sides thereof. The distribution plate is formed with at least one corrugation to define multiple passes of the first fluid along the distribution plate between the first and second plate. The first plate further includes a rib extending along at least a length thereof and adapted to define two passes and u-flow of a second fluid along the first plate. At least one of the first plate, the second plate and the distribution plate of each of the second plate assembly further comprises at least one of an additional aperture, an additional hole and an additional opening respectively being aligned with respect to each other to define an additional channel. The additional channel adapted to configure multiple flow passes along the height "H" of the heat exchanger core. The additional channel further adapted to improve distribution of the first fluid along in the distribution plates. The additional aperture corresponding to the additional opening is disposed proximal to one of the first set of apertures, particularly, first aperture corresponding to an outlet port along distal side of the heat exchanger core. Particularly, the additional aperture is at least partially disposed between extreme end of the rib and the periphery of the first set of apertures.

[0037] Although, the present invention is explained with example of a chiller used in vehicular environment, however, the present invention is applicable to any plate type heat exchanger used in vehicular and non-vehicular environments, wherein additional channel to configure multiple passes of first heat exchange fluid is required without detrimentally impacting the flow in the second fluid flow passages.

[0038] The present disclosure envisages a heat exchanger, particularly, a chiller 100 in accordance with an embodiment of the present invention. FIG. 1 illustrates a perspective view of the chiller 100 in accordance with an embodiment of the present invention. FIG. 2 illustrates a top view of the chiller 100. The chiller 100 is for heat exchange between a first fluid for example, a refrigerant, particularly, a high-pressure refrigerant and a second fluid, for example a coolant. The coolant extracts heat from a heat-generating element, for example, battery of an electric vehicle while being circulated through a battery-cooling module. The chiller cools the coolant received thereby from the battery-cooling module after the coolant extracted heat from the batteries. Particularly, the chiller cools the coolant circulating there through by heat exchange with a refrigerant circulating through different flow passages in the chiller and returns the cooled coolant to the battery-cooling module.

[0039] The chiller 100 comprises a heat exchanger core, simply referred to as core 100a, a first set of inlet and outlet ports 20a and 20b and a second set of inlet and outlet ports 30a and 30b. The second set inlet and outlet ports 30a and 30b as illustrated in FIG. 2 are arranged opposite to the first set of inlet and outlet ports 20a and 20b. The core 100a of the chiller 100 being disposed between a top reinforcement plate 60a and a bottom reinforcement plate 60b. The chiller 100 further limited between a distal side 100b and a proximal side 100c and a front side 100d and a rear side 100e. The core 100a comprises a stack of first plate assemblies 10 and a stack of second plate assemblies 11 to together define a height "H" of the core as depicted in FIG. 3. FIG. 3 illustrates a sectional view of the chiller 100 along sectional plane X-X' depicted in FIG.2. Also is illustrated an enlarged view of a section of the chiller 100 formed by assembling the second set of plate assemblies 11. FIG. 4 illustrates a side view of the chiller 100. FIG. 5- FIG. 7 illustrates sectional view of the chiller along different sections A-A', B-B' and C-C' Depicted in FIG. 4. The section B-B' passes through the second set of inlet and outlet ports 30a and 30b. The section C-C' passes through the first set of inlet and outlet ports 20a and 20b.The section A-A' passes through the intermediate portion of the heat exchanger core 100a between the first set of inlet and outlet ports 20a and 20b and the second set of inlet and outlet ports 30a and 30b. Generally, each plate assembly 10, 11 is adapted to define first flow passage 12, 13 between a first plate 10a, 11a and a second plate 10b, 11b thereof. Specifically, the first plate 10a and the second plate 10b of the first plate assembly 10 defines first flow passage 12 there-between. Similarly, the first plate 11a and the second plate 11b of the second plate assembly 11 defines first flow passage 13 there-between. Further, each plate assembly 10, 11 further adapted to define second flow passages 22, 23 with adjacent plate assemblies 10, 11 on opposite sides thereof. Specifically, the first plate assembly 10 is adapted to define second flow passages 22 with adjacent first plate assemblies 10 on opposite sides thereof. Similarly, the second plate assembly 11 is adapted to define second flow passages 23 with adjacent first plate assemblies 11 on opposite sides thereof.

[0040] At least one of the first plate assembly 10 and the second plate assembly 11 comprises at least two of the first plate 11a, the second plate 11b and a distribution plate 11c. At least one of the first plate 11a, the second plate 11b and the distribution plate 11c of each of the second plate assembly comprises at least one of an additional aperture 17a, an additional hole 17b and an additional opening 17c respectively being aligned with respect to each other to define an additional channel 33 as illustrated in FIG. 3. The additional channel 33 configures multiple flow passes along the height "H" of the heat exchanger core. More specifically, the additional channel 33 is adapted to configure three passes for the first fluid, particularly, the high-pressure refrigerant along the height "H" of the heat exchanger core. At least one of the three passes extends long the entire length of the heat exchanger 100. Further, the additional channel 33 assists in proper distribution of the first fluid in in the first flow passages 12.

[0041] At least one of the first plate assembly 10 and the second plate assembly 11 comprises at least two of the first plate 10a, 11a, the second plate 10b, 11b and a distribution plate 10c, 11c. FIG.8 illustrates an exploded view of a first plate assembly 10. Similarly, the FIG. 9 illustrates an exploded view of the second plate assembly 11.

[0042] Referring to the FIG. 10, the first plate 10a comprises a first planar portion 12a and a first peripheral wall 14a. The first planar portion 12a comprises a first set of apertures 16a, a second set of apertures 18a and a rib 19a extending along at least a portion of the length of the first plate 10a. The rib 19a extending from the portion of the peripheral wall 14a corresponding to the rear wall 100e of the chiller 100, particularly from portion of the peripheral wall 14a proximal to the second set of apertures 18a towards portion of the peripheral wall 14a proximal to the first set of apertures 16a.. The rib 19a adapted to define u-flow for configuring two passes of the second fluid, particularly, the coolant along the first planar portion 12a. Although, the first plate 11a of the second plate assembly 11 is structurally and functionally similar to the first plate 10a of the first plate assembly 10, however, the first plate 11a of the second plate assembly 11 illustrated in FG. 11, comprises the additional aperture 17a corresponding to the additional opening 17c. The additional aperture 17a is described in details in the forthcoming section of the specification with reference to FIG. 12.

[0043] Referring to the FIG. 13, the second plate 10b comprises the second planar portion 12b and the second peripheral wall 14b. The second plate 10b is adapted to be stacked with the first plate 10a such that the second planar portion 12b is spaced from the first planar portion 12a by spacing S. The second planar portion 12b comprises a first set of holes and a second set of holes. Although, the second plate 11b of the second plate assembly 11 is structurally and functionally similar to the second plate 10b of the first plate assembly 10, however, the second plate 11b of the second plate assembly 11 illustrated in FIG. 14 comprises the additional hole 17b corresponding to the additional opening 17c. The additional hole 17b is described in details in the forthcoming section of the specification.

[0044] Referring to the FIG. 15, the distribution plate 10c comprises a third planar portion 12c arranged between the first planar portion 12a and the second planar portion 12b. The distribution plate 10c formed with at least one corrugation 14c. The third planar portion 12c comprises a first set of openings 16c and a second set of openings 18c. Although, the distribution plate 11c of the second plate assembly 11 is structurally and functionally similar to the distribution plate 10c of the first plate assembly 10, however, the distribution plate 10c of the second plate assembly 11 as illustrated in FIG. 16 comprises the additional opening 17c described in details in the forthcoming section of the specification.

[0045] Referring to FIG. 6, the first set of openings 16c formed on at least one of the distribution plates 10c of the first plate 10 being aligned with respect to each other define a portion of first pair of channels 20. Similarly, referring to FIG. 7, the first set of openings 16c formed on at least one of the distribution plates 11c of the second plate assemblies 11 being aligned with respect to each other define the remaining portion of the first pair of channels 20. The second set of apertures 18a formed on the first plates 10a being aligned with respect to the second set of holes 18b formed on the second plates 10b to define a portion of the second pair of channels 30. The second set of apertures 18a formed on the first plates 11a of the second plate assemblies 11 being aligned with respect to the second set of holes 18b formed on the second plates 10b to define the remaining portion of second pair of channels 30. Referring to the FIG. 3, the additional apertures 17a, the additional hole 17b and the additional opening 17c respectively aligned with respect to each other to define the additional channel 33. At least one channel of the first set of channels 20 and the additional channel 33 comprises a barrier to direct the first fluid through first fluid passages 12 and 13 to define multiple flow passes along the height "H" of the chiller 100.

[0046] Further, the first pair of channels 20 and the additional channel 33 are adapted to be in fluid communication with the first flow passages 12 configured between the first and second plates 10a and 10b of the first plate assembly 10. Furthermore, the first pair of channels 20 and the additional channel 33 are adapted to be in fluid communication with the first flow passages 13 configured between the first and the second plates 11a and 11b of the second plate assemblies 11. Still further, the first pair of channels 20 and the additional channel 33 are in fluid isolation with the second flow passages 22, 23 defined by the multiple plate assemblies. Such arrangement of the first pair of channels 20 distributes and collects the first heat exchange fluid, particularly, the refrigerant with respect to the first flow passages 12 and 13. Similarly, the second pair of channels 30 are adapted to be in in fluid communication with the second flow passages 22 configured between adjacent first plate assemblies 10. Further, the second pair of channels 30 are adapted to be in fluid communication with the second flow passages 23 configured between adjacent second plate assemblies 11. Furthermore, the second pair of channels 30 are adapted to be in fluid isolation with the first flow passages 12,13 defined by the multiple plate assemblies 10, 11 respectively. Such arrangement of the second pair of channels 30 distributes and collects the second heat exchange fluid, particularly, the coolant with respect to the second flow passages 22, 23.

[0047] Referring to the FIG. 2, the top plate 50a and the top reinforcement plate 60a of the chiller 100 is formed with first set of inlet and outlet ports 20a and 20b and a second set of inlet and outlet ports 30a and 30b respectively. In accordance with one embodiment, the first inlet 20a and second outlet port 30b are disposed along a proximal side 100c of the chiller 100. Further, the first outlet 20b and second inlet port 30a are disposed along a distal side 100b of the chiller 100. Such arrangement provide counter flow between the first fluid, i.e. the refrigerant and the second fluid, i.e. the coolant. However, the present invention is not limited to the placement of the first and second inlet ports 20a and 20b and the first and second outlet ports 30a and 30b on the top plate 50a. The first set of inlet and outlet ports 20a and 20b respectively being in fluid communication with the first pair of channels 20 for ingress and egress of first fluid with respect to the first flow passages 12 and 13 configured by the first and second plate assemblies 10 and 11 respectively as illustrated in FIG. 7. The second set inlet and outlet ports 30a and 30b being in fluid communication with the second pair of channels for ingress and egress of second fluid with respect to the second flow passages 22 and 23 configured by the first and second plate assemblies 10 and 11 respectively as illustrated in FIG. 8.

[0048] Further, the first set of inlet and outlet ports 20a and 20b being in the form of openings on a top plate 50a and a top reinforcement plate 60a are in fluid communication with respective inlet and outlet connector blocks 22a and 22b respectively as illustrated in FIG. 6. The inlet and outlet connector blocks 22a and 22b are connected to first fluid flow conduits supplying and collecting the first fluid, particularly, the refrigerant with respect to the chiller 100.The second set of inlet and outlet ports 30a and 30b being in the form of openings on the top plate 50a and the top reinforcement plate 60a are in fluid communication with respective inlet and outlet nozzles 32a and 32b as illustrated in FIG. 7. The inlet and outlet nozzles 32a and 32b are connected to second fluid flow pipes supplying and collecting the second fluid, particularly, the coolant with respect to the chiller 100. Further, the chiller comprises an additional port 33a in the form of additional opening on the top plate 50a and the top reinforcement plate 60a. The additional port 33a adapted to configure fluid communication between the additional channel 33 on one side and a connector bore on other side. The connector bore configured within the outlet connector block 22b along distal side of the core 100a for being fluidically coupled to other fluid devices.

[0049] The additional aperture 17a corresponding to the additional opening 17c is at least partially disposed between extreme end of the rib 19a and the periphery of the first set of apertures 16a as illustrated in FIG. 11 and FIG. 12. Generally, the additional aperture 17a is disposed proximal to the first aperture 16a corresponding to the first outlet port 20b along distal side 100b of the core 100a of the chiller 100. Specifically, the additional aperture 17a is aligned to the first aperture 16a corresponding to the first outlet port 20b along distal side of the core 100a of the chiller 100. More specifically, the additional aperture 17a is disposed between the first outlet port 20a and the second inlet port 30a and along the length of the distribution plate 11c of the second plate assembly 11 and along distal side of the core 100a of the chiller 100. With such configuration and placement of the additional aperture 17a the coolant entering the second flow passages 22, 23 from the second inlet port 30a is directed to through the first pass and second pass along the rib 19a with minimum pressure drop. In accordance with an embodiment and as illustrated in FIG. 12, the additional aperture 17a is positioned at a distance "S" in the range of 1.5 to 3 times the diameter "d" of the first aperture 16a along distal side of the core 100a of the chiller 100. Further, the additional aperture 17a is positioned within an angle "α" subtended from a center "C" of the first aperture 16a along distal side of the core 100a of the chiller 100, the angle "α" being in the range of 15° to 45°. Furthermore, the present invention is not limited to any particular shape of the additional aperture 17a and the additional aperture 17a can be of any shape but not limited to circular, elliptical, square and rectangular as far as the additional aperture 17a facilitates unobstructed refrigerant flow through the additional channel 33. In accordance with an embodiment, the additional aperture 17a is formed on a raised platform that is offset from the plane of a first planar portion 13a.Such strategic placement and configuration of the additional aperture 17a prevents pressure drop in the second flow passages 23 configured between adjacent plate assemblies 11. Although the additional channel 33 formed by aligning the additional apertures 17a, the additional holes 17b and the additional openings 17c pass through the second flow passages 23, however, the additional channel 33 has minimal impact of the pressure drop of the coolant flowing along the first plates 11a due to proper positioning of the additional aperture 17a. The pressure drop of the coolant in the second flow passages 23 have adverse impact the performance of the chiller 100. The strategic positioning of the additional aperture 17a on the first planar portion 13a of the first plate 11 relative to the first aperture 16a addresses the pressure drop issue in the second flow passages 23, thereby improving efficiency and performance of the chiller 100.

[0050] Still further, the additional hole 17b corresponding to the additional aperture 17a is along the plane of the second planar portion 13b as illustrated in FIG. 14. Preferably, the additional opening 17c is at least partially surrounded by at least a portion of at least one corrugation 14c as illustrated in FIG. 16. The at least one corrugation 14c around the additional opening 17c on each of the distribution plate 10c forming at least a portion of the additional channel 33 provide sufficient contact between the first plate 10a, 11a and the second plate 10b, 11b of the corresponding plate assembly 10,11 to form secure joint between the first plate 10a, 11a and the second plate 10b, 11b. The secure connection between the first plate 10a, 11a and the second plate 10b, 11b enables the chiller 100 to withstand high-pressures of high pressure refrigerant flowing through the first fluid flow passages 12, 13.

[0051] Further, the heat exchanger comprises turbulators 40, 41 disposed between adjacent plate assemblies 10, 11. The first set of turbulators 40 illustrated in the FIG. 19 are disposed between adjacent first plate assemblies 10. The second set of turbulators 41 illustrated in the FIG. 20 are disposed between adjacent second plate assemblies 11. Particularly, first set of turbulators 40 are in form of spaced apart turbulator patches 40a and 40b disposed along the first planar portion 12a of each of the first plate 10a. The first set of turbulators 40 are disposed on opposite sides of the rib 19a formed on the first plate 10a. The first set of turbulators 40 are disposed between adjacent first plate assemblies 10. Similarly, the second set of turbulators 41 are in form of spaced apart turbulator patches 41a and 41b disposed along the first planar portion 13a of each of the first plate 11a. The second set of turbulators 41 are disposed on opposite sides of the rib 19a formed on the first plate 11a. The second set of turbulators 41 are disposed between adjacent second plate assemblies 11. Particularly, each of the second turbulators 41 comprises additional punched out section 47a in addition to first set of punched out sections 42a and second set of punched out sections 42b corresponding and aligned to the first set of apertures 16a and the second set of apertures 18a respectively formed on the first plate 11a. More specifically, the additional punched out section 47a is aligned to the additional aperture 17a.

Examples

Embodiment Construction

[0034]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.

[0035]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.

[0036]The present invention is explained with example of a chiller, wherein the chiller comprises a stack of first plate assemblies and a stack of second plate assemblies. The stack of second plate assemblies is stacked and fluidically connecte...

TECHNICAL FIELD

[0001] The present invention relates to a heat exchanger, more particularly, the present invention relates to a plate type chiller for use in an electric 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. The batteries are heated during operation thereof and required to be maintained within a desired temperature range. 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 and space efficient compared to tube type heat exchangers. Further, the plate type heat exchangers are cost effective 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 generally 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 hydrofluoroolefin 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. Although, the pressure drop of the refrigerant increases with the number of passes configured within the heat exchanger core, however, pressure drop for high-pressure refrigerant flowing within the heat exchanger has comparatively less adverse impact on performance of the heat exchanger compared to pressure drop for synthetic refrigerants. Accordingly, more number of refrigerant flow passes can be configured within the heat exchangers using high-pressure refrigerant to improve heat exchange between coolant and high-pressure refrigerant. The more number of passes can be configured by increasing the number of refrigerant flow passes along the plates of the heat exchanger and increasing the number of passes along the height of the heat exchanger core. However, configuring more number of passes of the high-pressure refrigerant along the plates and along height of the heat exchanger core is challenging as distribution of the refrigerant along the plates and different passes along the height of the core is difficult.

[0005] In order to improve the distribution of the refrigerant in the different passes along the plates and different passes along thickness of the heat exchanger core, a combination of first plate assemblies and second plate assemblies are used to configure the heat exchanger core. Each of the first and second plate assemblies comprises multiple plates to configure first flow passage and second flow passages adjacent to first flow passage. The plates of the second plate assemblies comprises an additional aperture in addition to the first set of apertures and second set of apertures formed on the plates of the first plate assemblies. The additional apertures on the plates of the second plate assemblies are aligned to each other to form additional channel. The additional channel in addition to the first and the second set of channels configured by aligning the first and second set of apertures is adapted to improve distribution of the refrigerant along the plates and the different passes along the height of the heat exchanger core. The additional channel inherently obstructs coolant flow in the second flow passages, particularly, the coolant flow passes, thereby creating dead zone and causing pressure drop for coolant flowing in the coolant flow passages. The increased pressure drop of coolant through the coolant flow passages decreases the overall flow of the coolant though the heat exchanger that in turn can adversely impact the performance of the heat exchanger.

[0006] Accordingly, there is a need for a plate type heat exchanger, particularly, a chiller formed by joining multiple plates, wherein the chiller is formed with an additional channel for improving refrigerant distribution in the multiple refrigerant flow passes formed along the plates and along height of the chiller with minimum impact of coolant flow in the second flow passages. Further, there is a need for a heat exchanger, particularly, chiller that is provided with arrangements for preventing pressure drop of coolant flowing through coolant flow passages configured within a heat exchanger, thereby improving efficiency and performance of the heat exchanger. Further, there is a need for a plate type heat exchanger that exhibits improved efficiency and performance.SUMMARY

[0007] A heat exchanger for a heat exchange between a first fluid and a second fluid is disclosed in accordance with an embodiment of the present invention. The heat exchanger comprising a heat exchanger core, a first set of inlet and outlet ports and a second set inlet and outlet ports. The heat exchanger core limited between a distal side and a proximal side and a front side and a rear side. The heat exchanger core comprising a stack of first plate assemblies and a stack of second plate assemblies together defining a height "H" of the heat exchanger core. At least one of the first plate assembly and the second plate assembly comprises at least two of a first plate, a second plate and a distribution plate. At least one of the first plate, the second plate and the distribution plate of each plate assembly comprises at least one of an additional aperture, an additional hole and an additional opening respectively aligned with respect to each other to define an additional channel. The additional channel configures multiple flow passes along the height "H" of the heat exchanger core. The additional aperture is at least partially disposed between extreme end of a rib and a periphery of a first aperture formed on the first plate.

[0008] At least one of the plate assembly comprises at least one of a first plate, a second plate and a distribution plate.

[0009] The first plate comprising a first planar portion and a first peripheral wall. The first planar portion comprises the first set of apertures, a second set of apertures and the rib extending along at least a portion of the length of the first plate. The rib adapted to define u-flow along the first planar portion. The first plate of the second plate assembly further comprising the additional aperture corresponding to the additional opening.

[0010] The second plate comprises the second planar portion and the second peripheral wall. The second planar portion is arranged spaced from the first planar portion and comprising a first set of holes and a second set of holes. The second plate of the second plate assembly further comprises the additional hole corresponding to the additional opening.

[0011] The distribution plate comprises a third planar portion arranged between the first planar portion and the second planar portion. The distribution plate formed with at least one corrugation and comprising a first set of openings and a second set of openings. The distribution plate of the second plate assembly further comprises the additional opening. The first set of openings formed on the distribution plates being aligned with respect to each other to define a first pair of channels, wherein at least one of the distribution plates is without at least one openings to create a barrier within at least one channel.

[0012] The second set of apertures formed on the first plates being aligned with respect to the second set of holes formed on the second plates to define a second pair of channels.

[0013] Generally, each plate assembly adapted to define first flow passage between the first and the second plates thereof. Further, each plate assembly adapted to define second flow passages with adjacent plate assemblies on opposite sides thereof.

[0014] Particularly, at least one of the first pair of channels and the additional channel are adapted to be in fluid communication with the first flow passages and in fluid isolation with the second flow passages defined by the multiple plate assemblies.

[0015] Similarly, the second pair of channels are adapted to be in in fluid communication with the second flow passages and in fluid isolation with the first flow passages defined by the multiple plate assemblies.

[0016] Further, the first set of inlet and outlet ports being in fluid communication with the first pair of channels for ingress and egress of first fluid with respect to the first flow passages. The second set inlet and outlet ports being in fluid communication with the second pair of channels for ingress and egress of second fluid with respect to the second flow passages.

[0017] Specifically, the additional channel is adapted to configure three passes for the first fluid along the height "H" of the heat exchanger core, at least one of the three passes extends along the length of the heat exchanger.

[0018] Generally, the first set of inlet and outlet ports being in the form of openings on a top plate and a top reinforcement plate that receive the heat exchanger core there-between, the first set of inlet and outlet ports are in fluid communication with respective inlet and outlet connector blocks.

[0019] The second set of inlet and outlet ports being in the form of openings on the top plate and the top reinforcement plate are in fluid communication with respective inlet and outlet nozzles.

[0020] Further, the heat exchanger comprises additional port in the form of additional opening on the top plate and the top reinforcement plate. The additional port adapted to configure fluid communication between the additional channel on one side and a connector bore on other side. The connector bore configured within the outlet connector block along distal side of the heat exchanger core.

[0021] Generally, the additional aperture is disposed proximal to the first aperture along the distal side of the heat exchanger core.

[0022] Specifically, the additional aperture is aligned to the first aperture along the distal side of the heat exchanger core.

[0023] More specifically, the additional aperture is disposed between the first aperture and the second aperture along distal side of the heat exchanger core.

[0024] In accordance with an embodiment, the additional aperture is positioned at a distance "S" from the first aperture along the distal side of the heat exchanger core, the distance "S" being in the range of 1.5 to 3 times the diameter "d" of the first aperture.

[0025] Further, the additional aperture is positioned within an angle "α" subtended from center "C" of the first aperture along the distal side of the heat exchanger core, the angle "α" being in the range of 15° to 45°.

[0026] Furthermore, the additional aperture can be of any shape but not limited to circular, elliptical, square and rectangular.

[0027] More specifically, the additional aperture is formed on a raised platform that is offset from the plane of the first planar portion.

[0028] Still further, the additional hole is along the plane of the second planar portion.

[0029] Preferably, the additional opening is at least partially surrounded by at least a portion of at least one corrugation.

[0030] Further, the heat exchanger comprises turbulators disposed between adjacent plate assemblies. Particularly, first set of turbulators are disposed between adjacent first plate assemblies. The second set of turbulators are disposed between adjacent second plate assemblies.

[0031] Particularly, each of the second turbulators comprises additional punched out section in addition to first set of punched out sections and second set of punched out sections corresponding and aligned to the first set of apertures and the second set of apertures respectively.

[0032] More specifically, the additional punched out hole is aligned to the additional aperture.BRIEF DESCRIPTION

[0033] 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 a perspective view of a heat exchanger, particularly, a chiller, in accordance with an embodiment of the present invention. FIG. 2 illustrates a top view of the chiller of the FIG. 1. FIG. 3 illustrates a sectional view of the chiller along sectional plane X-X' of FIG.2, also is illustrated an enlarged view of a top section of the chiller formed by assembling a second set of plate assemblies. FIG. 4 illustrates a side view of the chiller of the FIG. 1. FIG. 5 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line A-A' of FIG. 4. FIG. 6 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line B-B' of FIG. 4. FIG. 7 illustrates a sectional view of the chiller, also is depicted an enlarged view of the sectional view of the chiller along the section line C-C' of FIG. 4. FIG. 8 illustrates an exploded view of a first plate assembly in accordance with an embodiment of the present invention. FIG. 9 illustrates an exploded view of a second plate assembly in accordance with an embodiment of the present invention, wherein each of a first plate, a second plate and distribution plate of the second plate assembly is formed with an additional aperture, hole and opening. FIG. 10 and FIG. 11 depict perspective views of a first plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 12 illustrates top view of the second plate depicting relative position of an additional aperture with respect to a first aperture along distal side of the heat exchanger core FIG. 13 and FIG. 14 depict perspective views of a second plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 15 and FIG. 16 depict perspective views of a distributions plate of the first and second plate assemblies of FIG. 8 and FIG. 9 respectively. FIG. 17 and FIG. 18 depict top views of the distribution plates of FIG. 15 and FIG. 16 respectively. FIG. 19 depicts a perspective view of a first set of turbulators arranged between adjacent first plate assemblies, wherein exploded view of one such plate assembly is depicted in FIG. 8. FIG. 20 depicts a perspective view of a second set of turbulators arranged between second plate assemblies, wherein exploded view of one such plate assembly is depicted in FIG. 9. DETAILED DESCRIPTION

[0034] 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.

[0035] 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.

[0036] The present invention is explained with example of a chiller, wherein the chiller comprises a stack of first plate assemblies and a stack of second plate assemblies. The stack of second plate assemblies is stacked and fluidically connected to the stack of first plate assemblies to define a height "H" of the chiller core. The second plate assembly comprises at least one of a first plate, a second plate and a distribution plate to define a first fluid flow passage for first fluid, particularly refrigerant between the first and second plates and second fluid flow passages for second fluid, particularly coolant between adjacent second plate assemblies on opposite sides thereof. The distribution plate is formed with at least one corrugation to define multiple passes of the first fluid along the distribution plate between the first and second plate. The first plate further includes a rib extending along at least a length thereof and adapted to define two passes and u-flow of a second fluid along the first plate. At least one of the first plate, the second plate and the distribution plate of each of the second plate assembly further comprises at least one of an additional aperture, an additional hole and an additional opening respectively being aligned with respect to each other to define an additional channel. The additional channel adapted to configure multiple flow passes along the height "H" of the heat exchanger core. The additional channel further adapted to improve distribution of the first fluid along in the distribution plates. The additional aperture corresponding to the additional opening is disposed proximal to one of the first set of apertures, particularly, first aperture corresponding to an outlet port along distal side of the heat exchanger core. Particularly, the additional aperture is at least partially disposed between extreme end of the rib and the periphery of the first set of apertures.

[0037] Although, the present invention is explained with example of a chiller used in vehicular environment, however, the present invention is applicable to any plate type heat exchanger used in vehicular and non-vehicular environments, wherein additional channel to configure multiple passes of first heat exchange fluid is required without detrimentally impacting the flow in the second fluid flow passages.

[0038] The present disclosure envisages a heat exchanger, particularly, a chiller 100 in accordance with an embodiment of the present invention. FIG. 1 illustrates a perspective view of the chiller 100 in accordance with an embodiment of the present invention. FIG. 2 illustrates a top view of the chiller 100. The chiller 100 is for heat exchange between a first fluid for example, a refrigerant, particularly, a high-pressure refrigerant and a second fluid, for example a coolant. The coolant extracts heat from a heat-generating element, for example, battery of an electric vehicle while being circulated through a battery-cooling module. The chiller cools the coolant received thereby from the battery-cooling module after the coolant extracted heat from the batteries. Particularly, the chiller cools the coolant circulating there through by heat exchange with a refrigerant circulating through different flow passages in the chiller and returns the cooled coolant to the battery-cooling module.

[0039] The chiller 100 comprises a heat exchanger core, simply referred to as core 100a, a first set of inlet and outlet ports 20a and 20b and a second set of inlet and outlet ports 30a and 30b. The second set inlet and outlet ports 30a and 30b as illustrated in FIG. 2 are arranged opposite to the first set of inlet and outlet ports 20a and 20b. The core 100a of the chiller 100 being disposed between a top reinforcement plate 60a and a bottom reinforcement plate 60b. The chiller 100 further limited between a distal side 100b and a proximal side 100c and a front side 100d and a rear side 100e. The core 100a comprises a stack of first plate assemblies 10 and a stack of second plate assemblies 11 to together define a height "H" of the core as depicted in FIG. 3. FIG. 3 illustrates a sectional view of the chiller 100 along sectional plane X-X' depicted in FIG.2. Also is illustrated an enlarged view of a section of the chiller 100 formed by assembling the second set of plate assemblies 11. FIG. 4 illustrates a side view of the chiller 100. FIG. 5- FIG. 7 illustrates sectional view of the chiller along different sections A-A', B-B' and C-C' Depicted in FIG. 4. The section B-B' passes through the second set of inlet and outlet ports 30a and 30b. The section C-C' passes through the first set of inlet and outlet ports 20a and 20b.The section A-A' passes through the intermediate portion of the heat exchanger core 100a between the first set of inlet and outlet ports 20a and 20b and the second set of inlet and outlet ports 30a and 30b. Generally, each plate assembly 10, 11 is adapted to define first flow passage 12, 13 between a first plate 10a, 11a and a second plate 10b, 11b thereof. Specifically, the first plate 10a and the second plate 10b of the first plate assembly 10 defines first flow passage 12 there-between. Similarly, the first plate 11a and the second plate 11b of the second plate assembly 11 defines first flow passage 13 there-between. Further, each plate assembly 10, 11 further adapted to define second flow passages 22, 23 with adjacent plate assemblies 10, 11 on opposite sides thereof. Specifically, the first plate assembly 10 is adapted to define second flow passages 22 with adjacent first plate assemblies 10 on opposite sides thereof. Similarly, the second plate assembly 11 is adapted to define second flow passages 23 with adjacent first plate assemblies 11 on opposite sides thereof.

[0040] At least one of the first plate assembly 10 and the second plate assembly 11 comprises at least two of the first plate 11a, the second plate 11b and a distribution plate 11c. At least one of the first plate 11a, the second plate 11b and the distribution plate 11c of each of the second plate assembly comprises at least one of an additional aperture 17a, an additional hole 17b and an additional opening 17c respectively being aligned with respect to each other to define an additional channel 33 as illustrated in FIG. 3. The additional channel 33 configures multiple flow passes along the height "H" of the heat exchanger core. More specifically, the additional channel 33 is adapted to configure three passes for the first fluid, particularly, the high-pressure refrigerant along the height "H" of the heat exchanger core. At least one of the three passes extends long the entire length of the heat exchanger 100. Further, the additional channel 33 assists in proper distribution of the first fluid in in the first flow passages 12.

[0041] At least one of the first plate assembly 10 and the second plate assembly 11 comprises at least two of the first plate 10a, 11a, the second plate 10b, 11b and a distribution plate 10c, 11c. FIG.8 illustrates an exploded view of a first plate assembly 10. Similarly, the FIG. 9 illustrates an exploded view of the second plate assembly 11.

[0042] Referring to the FIG. 10, the first plate 10a comprises a first planar portion 12a and a first peripheral wall 14a. The first planar portion 12a comprises a first set of apertures 16a, a second set of apertures 18a and a rib 19a extending along at least a portion of the length of the first plate 10a. The rib 19a extending from the portion of the peripheral wall 14a corresponding to the rear wall 100e of the chiller 100, particularly from portion of the peripheral wall 14a proximal to the second set of apertures 18a towards portion of the peripheral wall 14a proximal to the first set of apertures 16a.. The rib 19a adapted to define u-flow for configuring two passes of the second fluid, particularly, the coolant along the first planar portion 12a. Although, the first plate 11a of the second plate assembly 11 is structurally and functionally similar to the first plate 10a of the first plate assembly 10, however, the first plate 11a of the second plate assembly 11 illustrated in FG. 11, comprises the additional aperture 17a corresponding to the additional opening 17c. The additional aperture 17a is described in details in the forthcoming section of the specification with reference to FIG. 12.

[0043] Referring to the FIG. 13, the second plate 10b comprises the second planar portion 12b and the second peripheral wall 14b. The second plate 10b is adapted to be stacked with the first plate 10a such that the second planar portion 12b is spaced from the first planar portion 12a by spacing S. The second planar portion 12b comprises a first set of holes and a second set of holes. Although, the second plate 11b of the second plate assembly 11 is structurally and functionally similar to the second plate 10b of the first plate assembly 10, however, the second plate 11b of the second plate assembly 11 illustrated in FIG. 14 comprises the additional hole 17b corresponding to the additional opening 17c. The additional hole 17b is described in details in the forthcoming section of the specification.

[0044] Referring to the FIG. 15, the distribution plate 10c comprises a third planar portion 12c arranged between the first planar portion 12a and the second planar portion 12b. The distribution plate 10c formed with at least one corrugation 14c. The third planar portion 12c comprises a first set of openings 16c and a second set of openings 18c. Although, the distribution plate 11c of the second plate assembly 11 is structurally and functionally similar to the distribution plate 10c of the first plate assembly 10, however, the distribution plate 10c of the second plate assembly 11 as illustrated in FIG. 16 comprises the additional opening 17c described in details in the forthcoming section of the specification.

[0045] Referring to FIG. 6, the first set of openings 16c formed on at least one of the distribution plates 10c of the first plate 10 being aligned with respect to each other define a portion of first pair of channels 20. Similarly, referring to FIG. 7, the first set of openings 16c formed on at least one of the distribution plates 11c of the second plate assemblies 11 being aligned with respect to each other define the remaining portion of the first pair of channels 20. The second set of apertures 18a formed on the first plates 10a being aligned with respect to the second set of holes 18b formed on the second plates 10b to define a portion of the second pair of channels 30. The second set of apertures 18a formed on the first plates 11a of the second plate assemblies 11 being aligned with respect to the second set of holes 18b formed on the second plates 10b to define the remaining portion of second pair of channels 30. Referring to the FIG. 3, the additional apertures 17a, the additional hole 17b and the additional opening 17c respectively aligned with respect to each other to define the additional channel 33. At least one channel of the first set of channels 20 and the additional channel 33 comprises a barrier to direct the first fluid through first fluid passages 12 and 13 to define multiple flow passes along the height "H" of the chiller 100.

[0046] Further, the first pair of channels 20 and the additional channel 33 are adapted to be in fluid communication with the first flow passages 12 configured between the first and second plates 10a and 10b of the first plate assembly 10. Furthermore, the first pair of channels 20 and the additional channel 33 are adapted to be in fluid communication with the first flow passages 13 configured between the first and the second plates 11a and 11b of the second plate assemblies 11. Still further, the first pair of channels 20 and the additional channel 33 are in fluid isolation with the second flow passages 22, 23 defined by the multiple plate assemblies. Such arrangement of the first pair of channels 20 distributes and collects the first heat exchange fluid, particularly, the refrigerant with respect to the first flow passages 12 and 13. Similarly, the second pair of channels 30 are adapted to be in in fluid communication with the second flow passages 22 configured between adjacent first plate assemblies 10. Further, the second pair of channels 30 are adapted to be in fluid communication with the second flow passages 23 configured between adjacent second plate assemblies 11. Furthermore, the second pair of channels 30 are adapted to be in fluid isolation with the first flow passages 12,13 defined by the multiple plate assemblies 10, 11 respectively. Such arrangement of the second pair of channels 30 distributes and collects the second heat exchange fluid, particularly, the coolant with respect to the second flow passages 22, 23.

[0047] Referring to the FIG. 2, the top plate 50a and the top reinforcement plate 60a of the chiller 100 is formed with first set of inlet and outlet ports 20a and 20b and a second set of inlet and outlet ports 30a and 30b respectively. In accordance with one embodiment, the first inlet 20a and second outlet port 30b are disposed along a proximal side 100c of the chiller 100. Further, the first outlet 20b and second inlet port 30a are disposed along a distal side 100b of the chiller 100. Such arrangement provide counter flow between the first fluid, i.e. the refrigerant and the second fluid, i.e. the coolant. However, the present invention is not limited to the placement of the first and second inlet ports 20a and 20b and the first and second outlet ports 30a and 30b on the top plate 50a. The first set of inlet and outlet ports 20a and 20b respectively being in fluid communication with the first pair of channels 20 for ingress and egress of first fluid with respect to the first flow passages 12 and 13 configured by the first and second plate assemblies 10 and 11 respectively as illustrated in FIG. 7. The second set inlet and outlet ports 30a and 30b being in fluid communication with the second pair of channels for ingress and egress of second fluid with respect to the second flow passages 22 and 23 configured by the first and second plate assemblies 10 and 11 respectively as illustrated in FIG. 8.

[0048] Further, the first set of inlet and outlet ports 20a and 20b being in the form of openings on a top plate 50a and a top reinforcement plate 60a are in fluid communication with respective inlet and outlet connector blocks 22a and 22b respectively as illustrated in FIG. 6. The inlet and outlet connector blocks 22a and 22b are connected to first fluid flow conduits supplying and collecting the first fluid, particularly, the refrigerant with respect to the chiller 100.The second set of inlet and outlet ports 30a and 30b being in the form of openings on the top plate 50a and the top reinforcement plate 60a are in fluid communication with respective inlet and outlet nozzles 32a and 32b as illustrated in FIG. 7. The inlet and outlet nozzles 32a and 32b are connected to second fluid flow pipes supplying and collecting the second fluid, particularly, the coolant with respect to the chiller 100. Further, the chiller comprises an additional port 33a in the form of additional opening on the top plate 50a and the top reinforcement plate 60a. The additional port 33a adapted to configure fluid communication between the additional channel 33 on one side and a connector bore on other side. The connector bore configured within the outlet connector block 22b along distal side of the core 100a for being fluidically coupled to other fluid devices.

[0049] The additional aperture 17a corresponding to the additional opening 17c is at least partially disposed between extreme end of the rib 19a and the periphery of the first set of apertures 16a as illustrated in FIG. 11 and FIG. 12. Generally, the additional aperture 17a is disposed proximal to the first aperture 16a corresponding to the first outlet port 20b along distal side 100b of the core 100a of the chiller 100. Specifically, the additional aperture 17a is aligned to the first aperture 16a corresponding to the first outlet port 20b along distal side of the core 100a of the chiller 100. More specifically, the additional aperture 17a is disposed between the first outlet port 20a and the second inlet port 30a and along the length of the distribution plate 11c of the second plate assembly 11 and along distal side of the core 100a of the chiller 100. With such configuration and placement of the additional aperture 17a the coolant entering the second flow passages 22, 23 from the second inlet port 30a is directed to through the first pass and second pass along the rib 19a with minimum pressure drop. In accordance with an embodiment and as illustrated in FIG. 12, the additional aperture 17a is positioned at a distance "S" in the range of 1.5 to 3 times the diameter "d" of the first aperture 16a along distal side of the core 100a of the chiller 100. Further, the additional aperture 17a is positioned within an angle "α" subtended from a center "C" of the first aperture 16a along distal side of the core 100a of the chiller 100, the angle "α" being in the range of 15° to 45°. Furthermore, the present invention is not limited to any particular shape of the additional aperture 17a and the additional aperture 17a can be of any shape but not limited to circular, elliptical, square and rectangular as far as the additional aperture 17a facilitates unobstructed refrigerant flow through the additional channel 33. In accordance with an embodiment, the additional aperture 17a is formed on a raised platform that is offset from the plane of a first planar portion 13a.Such strategic placement and configuration of the additional aperture 17a prevents pressure drop in the second flow passages 23 configured between adjacent plate assemblies 11. Although the additional channel 33 formed by aligning the additional apertures 17a, the additional holes 17b and the additional openings 17c pass through the second flow passages 23, however, the additional channel 33 has minimal impact of the pressure drop of the coolant flowing along the first plates 11a due to proper positioning of the additional aperture 17a. The pressure drop of the coolant in the second flow passages 23 have adverse impact the performance of the chiller 100. The strategic positioning of the additional aperture 17a on the first planar portion 13a of the first plate 11 relative to the first aperture 16a addresses the pressure drop issue in the second flow passages 23, thereby improving efficiency and performance of the chiller 100.

[0050] Still further, the additional hole 17b corresponding to the additional aperture 17a is along the plane of the second planar portion 13b as illustrated in FIG. 14. Preferably, the additional opening 17c is at least partially surrounded by at least a portion of at least one corrugation 14c as illustrated in FIG. 16. The at least one corrugation 14c around the additional opening 17c on each of the distribution plate 10c forming at least a portion of the additional channel 33 provide sufficient contact between the first plate 10a, 11a and the second plate 10b, 11b of the corresponding plate assembly 10,11 to form secure joint between the first plate 10a, 11a and the second plate 10b, 11b. The secure connection between the first plate 10a, 11a and the second plate 10b, 11b enables the chiller 100 to withstand high-pressures of high pressure refrigerant flowing through the first fluid flow passages 12, 13.

[0051] Further, the heat exchanger comprises turbulators 40, 41 disposed between adjacent plate assemblies 10, 11. The first set of turbulators 40 illustrated in the FIG. 19 are disposed between adjacent first plate assemblies 10. The second set of turbulators 41 illustrated in the FIG. 20 are disposed between adjacent second plate assemblies 11. Particularly, first set of turbulators 40 are in form of spaced apart turbulator patches 40a and 40b disposed along the first planar portion 12a of each of the first plate 10a. The first set of turbulators 40 are disposed on opposite sides of the rib 19a formed on the first plate 10a. The first set of turbulators 40 are disposed between adjacent first plate assemblies 10. Similarly, the second set of turbulators 41 are in form of spaced apart turbulator patches 41a and 41b disposed along the first planar portion 13a of each of the first plate 11a. The second set of turbulators 41 are disposed on opposite sides of the rib 19a formed on the first plate 11a. The second set of turbulators 41 are disposed between adjacent second plate assemblies 11. Particularly, each of the second turbulators 41 comprises additional punched out section 47a in addition to first set of punched out sections 42a and second set of punched out sections 42b corresponding and aligned to the first set of apertures 16a and the second set of apertures 18a respectively formed on the first plate 11a. More specifically, the additional punched out section 47a is aligned to the additional aperture 17a.

Examples

Embodiment Construction

[0034]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.

[0035]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.

[0036]The present invention is explained with example of a chiller, wherein the chiller comprises a stack of first plate assemblies and a stack of second plate assemblies. The stack of second plate assemblies is stacked and fluidically connecte...

Claims

1. A heat exchanger (100) for a heat exchange between a first fluid and a second fluid, the heat exchanger (100) comprising: • a heat exchanger core (100a) limited between a distal side (100b) and a proximal side (100c) and front side (100d) and a rear side and (100e), the heat exchanger core (100a) comprising at least one of a stack of first plate assemblies (10) and a stack of second plate assemblies (11) together defining a height "H" of the heat exchanger core (100a), • a first set of inlet and outlet ports (20a) and (20b); and • a second set inlet and outlet ports (30a) and (30b), characterized in that at least one of the first plate assembly (10) and the second plate assembly (11) comprises at least two of a first plate (10a, 11a), a second plate (10a, 11b) and a distribution plate (10c, 11c), wherein at least one of the first plate (10a, 11a), the second plate (10b, 11b) and the distribution plate (10c, 11c) of each plate assembly (10, 11) comprises at least one of an additional aperture (17a), an additional hole (17b) and an additional opening (17c) respectively aligned with respect to each other to define an additional channel (33) that configures multiple flow passes along the height "H" of the heat exchanger core (100a), wherein the additional aperture (17a) is at least partially disposed between extreme end of a rib (19a) and the periphery of a first set of apertures (16a) formed on the first plate (11a).

2. The heat exchanger (100) as claimed in the previous claim, wherein at least one plate assembly (10, 11) comprises at least one of: • a first plate (10a, 11a) comprising: ∘ a first planar portion (12a, 13a) comprising the first set of apertures (16a), a second set of apertures (18a) and the rib (19a) extending along at least a portion of the length of the first planar portion (12a, 13a) and adapted to define u-flow along the first planar portion (12a, 13a), the first plate (11a) of the second plate assembly (11) further comprising the additional aperture (17a) corresponding to the additional opening (17c), ∘ a first peripheral wall (14a, 15a), • a second plate (10b, 11b) comprising: ∘ a second planar portion (12b, 13b) arranged spaced from the first planar portion (12a, 13a) and comprising a first set of holes (16b) and a second set of holes (18b), the second plate (11b) of the second plate assembly (11) further comprises the additional hole (17b) corresponding to the additional opening (17c) ∘ a second peripheral wall (14b, 15b), • a distribution plate (10c, 11c) comprising ∘ a third planar portion (12c, 13c) arranged between the first planar portion (12a, 13a) and the second planar portion (12b, 13b), the distribution plate (10c, 11c) formed with at least one corrugation (14c) and comprising a first set of openings (16c) and a second set of openings (18c), the distribution plate (11c) of the second plate assembly (11) further comprises the additional opening (17c), wherein the first set of openings (16c) formed on the distribution plates (10c) being aligned with respect to each other to define a first pair of channels (20), wherein at least one of the distribution plates (16c) is without at least one openings (16c, 17c) to create a barrier within at least one channel (20, 33); and wherein the second set of apertures (18a) formed on the first plates (10a) being aligned with respect to the second set of holes (18b) formed on the second plates (10b) to define a second pair of channels (30),3. The heat exchanger (100) as claimed in any the previous claim, wherein each plate assembly (10, 11) adapted to define first flow passage (12, 13) between the first plates (10a, 11a) and the second plates (10b, 11b) thereof, each plate assembly (10, 11) further adapted to define second flow passages (22, 23) with adjacent plate assemblies (10,11) on opposite sides thereof.

4. The heat exchanger (100) as claimed in the previous claim, wherein the first pair of channels (20) and the additional channel (33) are adapted to be in fluid communication with the first flow passages (12, 13) and in fluid isolation with the second flow passages (22, 23) defined by the multiple plate assemblies (10, 11).

5. The heat exchanger (100) as claimed in the claim 3, wherein the second pair of channels (30) are adapted to be in in fluid communication with the second flow passages (22, 23) and in fluid isolation with the first flow passages (12, 13) defined by the multiple plate assemblies (10, 11).

6. The heat exchanger (100) as claimed in claim 2, wherein first set of inlet and outlet ports (20a) and (20b) being in fluid communication with the first pair of channels (20) for ingress and egress of first fluid with respect to the first flow passages (12, 13), whereas the second set of inlet and outlet ports (30a) and (30b) being in fluid communication with the second pair of channels (30) for ingress and egress of second fluid with respect to the second flow passages (22, 23).

7. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional channel (33) is adapted to configure three passes for the first fluid along the height "H" of the heat exchanger core (100a), at least one of the three passes extends along the length of the heat exchanger (100).

8. The heat exchanger (100) as claimed in any of the preceding claims, the first set of inlet and outlet ports (20a) and (20b) being in the form of openings on a top plate (50a) and a top reinforcement plate (60a) receiving the heat exchanger core (100a) there between, the first set of inlet and outlet ports (20a) and (20b) being in fluid communication with respective inlet and outlet connector blocks (22a) and (22b), whereas the second set of inlet and outlet ports (30a) and (30b) being in the form of openings on the top plate (50a) and the top reinforcement plate (60a) are in fluid communication with respective inlet and outlet nozzles (32a) and (32b).

9. The heat exchanger (100) as claimed in the previous claim, further comprises an additional port (33a) in the form of additional opening on the top plate (50a) and the top reinforcement plate (60a), the additional port adapted to configure fluid communication between additional channel (33) on one side and additional bore on other side, the additional bore being configured within the outlet connector block (22b) disposed along the distal side (100b) of the heat exchanger core (100a).

10. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) is disposed proximal to the first aperture (16a) along the distal side (100b) of the heat exchanger core (100a).

11. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) is aligned to the first aperture (16a) along the distal side (100b) of the heat exchanger core (100a).

12. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) is disposed between first aperture (16a) and the second aperture (18a) along the distal side (100b) of the heat exchanger core (100a).

13. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) is positioned at a distance "S" from the first aperture (16a) along the distal side (100b) of the heat exchanger core (100a), the distance "S" being in the range of 1.5 to 3 times the diameter "d" of the first aperture (16a).

14. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) is positioned within an angle "α" subtended from center "C" of the first aperture (16a) along the distal side (100b) of the heat exchanger core (100a), the angle "α" being in the range of 15° to 45°.

15. The heat exchanger (100) as claimed in any of the preceding claims, wherein the additional aperture (17a) can be of any shape but not limited to circular, elliptical, square and rectangular.

Images