The present invention relates to a heat exchanger, more particularly, the present invention relates to a chiller for battery cooling in electric vehicle.

With evolution of vehicles toward hybrid and pure electric vehicles, there is a need for cooling of power electronics and battery packs powering such vehicles along with a Heating Ventilation and Air Conditioning (HVAC) system for such vehicles. Accordingly, there is need for heat exchangers, particularly, a chiller. The chiller is used for at least one of battery cooling or cooling of power electronic based elements depending on the requirements.

The chiller generally handles a first heat exchange fluid, particularly, a refrigerant and a second heat exchange fluid, particularly, a coolant, and configures a refrigerant circuit disposed between a pair of coolant circuits. More specifically, the refrigerant circuit is in form of a plurality of sets of tubular elements that configure fluid flow passages for the first heat exchange fluid, particularly, the refrigerant and is sandwiched between coolant flow passages. The chiller includes a core formed by arranging the coolant flow passages with respect to the sets of tubular elements. The coolant flow passages are so arranged with respect to the set of tubular elements that at least one set of tubular elements is sandwiched between the pair of coolant flow passages. The coolant flow passages are also formed with fin elements to retard flow through the coolant flow passages and achieve heat transfer between the coolant flowing through the coolant flow passages and refrigerant flowing through the tubular elements. Particularly, the coolant after extracting heat from the battery pack of an electric vehicle or any other heat generating system is directed to flow through the coolant flow passages, wherein the coolant is cooled by virtue of heat exchange with refrigerant flowing through the refrigerant circuit. The cooled coolant is directed to the battery pack or the heat generating system to again extract heat from the battery pack, thereby ensuring a regular supply of cool coolant to the battery pack. The regular cooling of the battery pack prevents damage thereto due to over-heating and ensures efficient operation thereof.

Generally, each one of a first and a second coolant flow passages disposed at extreme ends of the core is in contact with only one set of tubular elements disposed at one side thereof. Accordingly, coolant flowing through each one of the first and the second coolant flow passages is subjected to heat exchange with refrigerant flowing through only one set of tubular elements that forms a part of the refrigerant circuit. Particularly, the coolant flowing through each one of the first and the second coolant flow passages is subjected to heat exchange from one side only and such heat exchange is inefficient heat exchange. Whereas, each one of the centrally disposed coolant flow passages is in contact with two sets of tubular elements, one on each side thereof. Accordingly, coolant flowing through each one of the centrally disposed coolant flow passages is capable of heat exchange with refrigerant flowing through two adjacent set of tubular elements, each set of tubular elements disposed on opposite sides thereof and forming a part of the refrigerant circuit. Particularly, the coolant flowing through each one of the centrally disposed coolant flow passages is subjected to heat exchange from both sides and such heat exchange is efficient heat exchange.

Due to inherent construction of the core, the second heat exchange fluid passes through a first and a second coolant flow passages at extreme ends of the core, thereby reducing flow of the second heat exchange fluid through the centrally disposed coolant flow passages and detrimentally impacting the heat exchange efficiency and performance of the chiller. Further, the second heat exchange fluid received in the housing bypasses the core through gap between the core and the housing, thereby detrimentally impacting the heat exchange. The problem of leakage between the core and the housing in aggravated in case gap between the core and the housing is more due to tolerances considering plastic parts and welding between the parts. Such configuration of the conventional chiller results in reduced efficiency and performance. Few prior art suggest using foam in gap between core and housing to prevent leakage from the gap between the core and the housing, however, such arrangement is complicated and requires additional elements such as foam.

Accordingly, there is a need for a chiller that achieves efficient heat exchange between a first heat exchange fluid, particularly, a refrigerant flowing through sets of tubular elements forming part of a refrigerant circuit and a second heat exchange fluid flowing through flow passages sandwiching at least one set of tubular elements and forming part of a coolant circuit. Further, there is a need for a chiller configured with a sealing arrangement for achieving sealing between a housing and a core received in the housing to prevent second heat exchange fluid from bypassing the core. Further, there is a need for a chiller configured with a sealing arrangement for achieving sealing between a housing and a core without requiring additional elements such as foam for achieving the sealing. Still further, there is a need for a chiller configured with an arrangement for restricting flow of second heat exchange fluid through a first and a second coolant flow passages disposed at extreme ends of the core. Furthermore, there is a need for a chiller configured with an arrangement for promoting flow of second heat exchange fluid through coolant flow passages centrally disposed with respect to the core. Still further, there is a need for a chiller that involves an arrangement for sealing gap between core and the housing, wherein the arrangement is simple in construction, involves fewer parts, is reliable and inexpensive.

An object of the present invention is to provide a chiller that obviates the drawbacks associated with-other chillers.

Another object of the present invention is to provide a chiller that achieves improved heat exchange between a first heat exchange fluid, particularly, a refrigerant flowing through sets of tubular elements forming part of a refrigerant circuit and a second heat exchange fluid flowing through flow passages sandwiching at least one set of tubular elements and forming part of a coolant circuit. Another object of the present invention is to provide a chiller configured with a sealing arrangement for achieving sealing between a housing and a core received in the housing to prevent second heat exchange fluid from bypassing the core.

Yet another object of the present invention is to provide a chiller configured with a sealing arrangement for achieving sealing between a housing and a core without requiring additional elements such as foam for achieving the sealing.

Still another object of the present invention is to provide a chiller configured with an arrangement for restricting flow of second heat exchange fluid through a first and a second coolant flow passages at extreme ends of the core.

Still another object of the present invention is to provide a chiller configured with an arrangement for promoting flow of second heat exchange fluid through coolant flow passages centrally disposed with respect to the core.

Another object of the present invention is to provide a chiller that exhibits improved efficiency and performance.

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 which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms 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.

A heat exchanger is disclosed in accordance with an embodiment of the present invention. The heat exchanger includes a core and a housing. The core includes sets of tubular elements and a plurality of fluid flow passages. The sets of tubular elements are in fluid communication with a first pair of inlet and outlet to define first fluid flow there-though. The plurality of fluid flow passages are receiving fins therein. The plurality of fluid flow passages are in fluid communication with a second pair of inlet and outlet to define second fluid flow there-though. The fluid flow passages sandwich at least one set of tubular elements. The housing includes a first portion and a second portion assembled to form an enclosure and receive the core therein to define an assembled configuration of the core and the housing. The housing includes a plurality of ribs that extend from at least one of a first face and a second face of the housing respectively towards the core received in the housing. The ribs extending from at least one of the first face and the second face includes extended ribs that limit fluid flow through gap between the core received in the housing and at least one of the respective first face and the second face in the assembled configuration. At least one first fin and at least one second fin disposed in respective first and second fluid flow passages at extreme ends of the core is deformed to at least partially disrupt fluid flow through the respective first and second fluid flow passages.

Specifically, at least one of the extended ribs interacts with and deforms at least one of the corresponding first fin and the second fin in the assembled configuration.

Alternatively, the at least one first fin and the at least one second fin are deformed before assembly between the housing and the core.

Generally, the core is a metallic core.

Specifically, the housing is either one of plastic material and metal.

Generally, the housing includes a top portion and a bottom portion that are assembled together by either one of vibration welding, ultrasonic soldering, ultrasonic welding and using threaded fasteners to form the enclosure to receive the core therein. Specifically, the at least one first fin and the at least one second fin are of same configuration and material as that of other fins.

Alternatively, the at least one first fin and the at least one second fin are of different configuration and material than that of other fins.

Generally, the extended ribs extending from the first face interact with and deform the corresponding at least one first fin to form sealing between a top portion of the core and the housing and also disrupt fluid flow through the respective first fluid flow passage.

Alternatively, the extended ribs extending from the second face interact with and deform the corresponding at least one second fin to form sealing between a bottom portion of the core and the housing and also disrupt fluid flow through the respective second fluid flow passage.

Generally, at least one first and second fins are of deformable material and are of such configuration that facilitates deformation thereof upon interaction with respective extended ribs in the assembled configuration to prevent deformation of the other elements of the core.

Further, the extended ribs and the respective at least one first fin and the at least one second fin so contact each other such that forces exerted by the extended ribs in the assembled configuration are dissipated in deforming the at least one first fin and the at least one second fin and are prevented from being transmitting through the at least one first fin and the at least one second fin to deform other elements of the core. Furthermore, the heat exchanger includes locating elements to ensure interaction between the extended ribs and the respective at least one first fin and the at least one second fin in the assembled configuration.

In accordance with an embodiment, the extended ribs are in the form of teeth.

Also, is disclosed a method for assembling a heat exchanger. The method includes the steps of receiving at least a portion of a core inside an enclosure defined by side-walls of either one of a top portion and a bottom portion of a housing. Thereafter, supporting either one of the top portion and the bottom portion of the housing in an inverted configuration thereof along with the core received therein inside a holder. Subsequently, aligning a portion of the housing other than the one supported in the holder with the portion of the housing supported inside the holder and joining the complimentary and aligned portions of the housing by either one of vibration welding, ultrasonic soldering, ultrasonic welding and using threaded fasteners to define an assembled configuration of the housing and the core, wherein in the assembled configuration extended ribs extend from at least one of first face and second face to at least one of top and bottom of the core to form sealing between the core and the housing. Finally, deforming at least one of first fins received in a first coolant flow passage and second fins received in a second coolant flow passage of the core either one of during assembly and before assembly to disrupt fluid flow through at least one of the respective first coolant flow passage and the second coolant flow passage.

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 detailed description when considered in connection with the accompanying figures, wherein: FIG.1 illustrates a schematic representation depicting internal details of a chiller in accordance with an embodiment of the present invention;

FIG. 2a illustrates an isometric view of a chiller in accordance with an embodiment of the present invention;

FIG. 2b illustrates a top view of the chiller of FIG. 2a;

FIG. 3 illustrates a sectional view of the chiller along section line A-A’ depicted in FIG. 2b;

FIG. 4 illustrates an isometric view of the chiller without the housing for depicting internal details of the chiller;

FIG. 5a illustrates an isometric view of a first portion of a housing with extended ribs configured on a first face thereof;

FIG. 5b illustrates an isometric view of a second portion of a housing with extended ribs configured on a second face thereof; and

FIG. 6 illustrates a flow diagram depicting a method of assembling a heat exchanger in accordance with an embodiment of the present invention, and various steps involved in such method.

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

The present invention in the forthcoming description and accompanying drawings is described with example of a chiller that includes a core received inside a housing. The core includes sets of tubular elements sandwiched between fluid flow passages. Particularly, a first heat exchange fluid, such as for example, a refrigerant flows through the sets of tubular elements to form at least a part of a refrigerant circuit and a second heat exchange fluid, such as for example, a coolant flows through the fluid flow passages to form at least a part of a coolant circuit. The housing includes a first part and a second part, wherein extending ribs from at least one of the first part and the second part extend up to at least one of the respective top and bottom of the core received in the housing to prevent leakage of the second heat exchange fluid between the housing and the core. The extending ribs from at least one of the first part and the second part further deform at least one of the respective first fin and the second fin disposed in respective first and second coolant flow passages at extreme ends of the core to at least partially disrupt fluid flow through the respective first and second fluid flow passages. However, the present invention is also applicable for any other heat exchanger other than the chiller, wherein it is required to prevent leakage between the core and the housing and prevent flow through flow passages disposed at extreme ends of the core to achieve efficient heat exchange and improved performance of the heat exchanger.

Referring to FIG. 1, a schematic cross sectional representation depicting internal details of a heat exchanger, particularly, a chiller 100 is illustrated. The chiller 100 includes a core 110 received inside a housing 122. FIG. 2a illustrates an isometric view of the chiller 100 in accordance with an embodiment of the present invention. FIG. 2b illustrates a top view of the chiller 100. FIG. 3 illustrates a sectional view of the chiller 100 along section line A-A’ depicted in FIG. 2b. FIG. 4 illustrates an isometric view of the chiller 100 without the housing 122 for depicting internal details of the chiller 100.

The core 110 includes sets of tubular elements 112a, 112b sandwiched between fluid flow passages, wherein a first heat exchange fluid, particularly, a refrigerant flows through the sets of tubular elements 112a, 112b and a second heat exchange fluid, particularly a coolant flows through the fluid flow passages, also referred to as coolant flow passages. Generally, the core 110 is of metallic material. In the forthcoming section of the specification, the refrigerant circuit and the various elements forming the refrigerant circuit are explained. Particularly, the forthcoming section describes connection of the tubular elements 112a, 112b, particularly, connection of inlet tubular elements 112a with an inlet 114a through an inlet manifold 114c of a manifold 114 and connection of outlet tubular elements 112b with an outlet 114b through an outlet manifold 114d of the manifold 114. Referring to the FIG. 4, as the connection between the inlet tubular elements 112a and the inlet manifold 114c, the connection between the outlet tubular elements 112b and the outlet manifold 114d and the connection between the inlet 114a and the outlet 114b with the inlet manifold 114c and the outlet manifold 114d respectively are not within the scope of the present invention and as such are not described in details for the sake of brevity of the present document.

The tubular elements of each set of tubular elements 112 are divided into inlet tubular elements 112a and corresponding outlet tubular elements 112b. More specifically, the inlet tubular elements 112a and the corresponding outlet tubular elements 112b are separated by a central baffle “C” extending along length thereof as illustrated in FIG. 4. The inlet tubular elements 112a and the corresponding outlet tubular elements 112b are interconnected to each other at one end either directly or indirectly by an intermediate manifold 130 to form set of tubular elements. Each set of tubular elements 112a, 112b forms fluid communication between the inlet manifold 114c and the outlet manifold 114d. The inlet manifold 114c receives refrigerant from the inlet 114a and distributes the refrigerant to the inlet tubular elements 112a of the sets of tubular elements. The refrigerant received in the inlet tubular elements 112a flows there through, reaches the outlet tubular element 112b connected to the inlet tubular element 112a and egresses the outlet tubular element 112b to the outlet manifold 114d, in the process the refrigerant undergoes heat exchange with coolant flowing through adjacent coolant flow passages. The refrigerant collected in the outlet manifold 114d after undergoing heat exchange with coolant flowing through the adjacent coolant flow passages egresses through the outlet 114b. In accordance with an embodiment of the present invention, the inlet tubular elements 112a and outlet tubular elements 112b are configured of micro multiport panels that are capable of receiving R744 as refrigerant and withstanding high operating pressures in range of 150 to 190 bars. Such a configuration of the inlet tubular elements 112a and outlet tubular elements 112b configured of micro multiport panels, renders the inlet tubular elements 112a and the outlet tubular elements 112b lighter in weight, safe and compact. However, the present invention is not limited to any particular configuration of the inlet tubular elements 112a and the outlet tubular elements 112b.

In one example, the inlet tubular elements 112a and the outlet tubular elements 112b are connected to each other indirectly by the intermediate manifold 130. More specifically, the inlet tubular elements 112a are supported between and forms fluid communication between the inlet manifold 114c and the intermediate manifold 130, whereas, the outlet tubular elements 112b are supported between and forms a reverse fluid communication between the intermediate manifold 130 and the outlet manifold 114d. Such configuration of the inlet tubular elements 112a and outlet tubular elements 112b of each set of tubular elements forms fluid communication between the inlet manifold 114c and the outlet manifold 114d.

In another example, the inlet tubular elements 112a and the outlet tubular elements 112b are connected to each other directly. Specifically, the inlet manifold 114c and the outlet manifold 114d are connected by at least one tubular element forming a continuous fluid flow path connecting the inlet manifold 114c and the outlet manifold 114d. More specifically, instead of the separate inlet tubular elements 112a and the outlet tubular elements 112b connected by the intermediate manifold 130 forming connection between the inlet manifold 114c and the outlet manifold 114d, a plurality of continuous tubular elements forms continuous fluid flow paths connecting the inlet manifold 114c to the outlet manifold 114d. Similar sets of tubular elements configure numerous refrigerant flow paths forming fluid communication between the inlet manifold 114c and the outlet manifold

114d.

The fluid flow passages, particularly, the coolant flow passages receive fins 118 therein and are in fluid communication with a second pair of inlet 120a and outlet 120b to define coolant flow there-though. The coolant flow passages can be formed by panels, however, the present invention is not limited to any particular arrangement for forming the fluid flow passages. The coolant flow passages receives coolant to allow coolant flow there-through. In accordance with an embodiment, the coolant is water glycol mixture. The coolant flowing through the coolant flow passages can be same or different coolant. The coolant flow passages 116 sandwich the at least one set of tubular elements 112a, 112b.

With such configuration, each one of a first coolant flow passage 116a and a second coolant flow passage 116b disposed at extreme ends of the core 110 is in contact with only one set of tubular elements 112a, 112b on one side thereof. Accordingly, the coolant flowing through each one of the first and the second coolant flow passages 116a and 116b is subjected to heat exchange from one side only and such heat exchange is inefficient heat exchange. Whereas, in case of the centrally disposed coolant flow passages 116 other than the first and the second coolant flow passages 116a and 116b disposed at extreme ends of the core 110, each one of the centrally disposed coolant flow passages 116 is in contact with two sets of tubular elements 112a, 112b, one on each side thereof. Accordingly, coolant flowing through each one of the centrally disposed coolant flow passages 116 is subjected to heat exchange with refrigerant flowing through two adjacent sets of tubular elements 112a, 112b, each set of tubular elements 112a, 112b disposed on opposite sides thereof and forming a part of the refrigerant circuit. Particularly, the coolant flowing through each one of the centrally disposed coolant flow passages 116 is subjected to heat exchange from both sides and such heat exchange is efficient heat exchange. Further, the efficiency and performance of the chiller is also reduced due to leakage of the coolant between the housing 122 and the core 110, particularly, between housing and the top and bottom of the core 110. Further, experimental data suggest that more coolant flows through the first and the second coolant flow passages 116a and 116b as compared to the centrally disposed coolant flow passages.

Considering the above and in order to improve the efficiency and performance of the chiller 100, it is required that coolant leakage between the housing 122 and the core 110, particularly, top and bottom of the core 110 is prevented. In order to further improve the efficiency and performance of the chiller 100, it is required that more coolant flows through the centrally disposed coolant flow passages 116 instead of the first and the second coolant flow passages 116a and 116b disposed at the at extreme ends of the core 110.

The housing 122 includes a first portion 122a and a second portion 122b assembled to form an enclosure to receive the core 110 therein to define an assembled configuration of the core 110 and the housing 122. However, the present invention is not limited to any particular configuration of the housing 112 as far as the housing 122 is formed of multiple parts that can be assembled together to form the enclosure to receive the core 110 therein. Generally, the housing 122 is of plastic material. Alternatively, the housing 122 is of metal. At least one of the first portion 122a and the second portion 122b, particularly, at least one of a first face 122c of the first portion 122a and a second face 122d of the second portion 122b includes ribs 124 extending therefrom and extending towards the core 110 received in the housing 122. The ribs 124 extending from the first face 122c and the second face 122d include first and second extended ribs 124a and 124b respectively, simply referred to as extended ribs 124a and 124b that extend up to the respective top and the bottom of the core 110 received inside the housing 122. Fig. 5a illustrates the first extended ribs 124a extending from the first face 122c of the first portion 122a of the housing 122. Similarly, the FG. 5b illustrates the second extended ribs 124b extending from the second face 122d of the second portion 122b of the housing 122. The first and the second extended ribs 124a and 124b are orthogonally protruding from the first face 122c of the first portion 122a and the second face 122d of the second portion 122b respectively. More specifically, the first extended ribs 124a and the second extended ribs 124b are extending up to the respective top and bottom of the core 110 received in the enclosure formed by assembling the first portion 122a and the second portion 122b of the housing 122. Further, the first extended ribs 124a are extending along the width of the first portion 122a and the second extended rib 124b are extending along the width of the second portion 122b. Generally, the ribs 124 including the first extended ribs 124a and the second extended ribs 124b are integrally formed on the respective first face 112c and the second face 122d of the housing 122 during molding of the housing 122 itself. As such any special process is not required for forming the ribs 124 including the extended ribs 124a and 124b on the respective first face 122c and the second face 122d. In accordance with an embodiment of the present invention, the the first extended ribs 124a and the second extended ribs 124b are in form of teeth. However, the present invention is not limited to particular configuration of the first extended ribs 124a and the second extended ribs 124b as far as the first extended ribs 124a and the second extended ribs 124b are capable of extending up to, interacting with and deforming at least one first fin 118a and at least one second fin 118b respectively to prevent leakage between the core 110 and the housing 122 and disrupt flow through the first coolant flow passage 116a and the second coolant flow passage respectively.

Preferably, the first portion 122a of the housing 122 is a top portion and the second portion 122b of the housing 122 is a bottom portion. The first portion 122a and the second portion 122b are joined together by either one of vibration welding, ultrasonic soldering, ultrasonic welding and using threaded fasteners to form the enclosure to receive the core 110 therein and define the assembled configuration of the housing 122 with respect to the core 110. However, the present invention is not limited to any particular method for forming joint between the first portion 122a and the second portion 122b of the housing 122 to define the assembled configuration of the housing 122 with respect to the core 110.

In the assembled configuration of the housing 122 with respect to the core 110, at least one of the first and the second extended ribs 124a and 124b extend from at least one of the first face 122c and the second face 122d respectively to at least one of the respective top and bottom of the core 110. Accordingly, in the assembled configuration of the housing 122 with respect to the core 110, at least one of the first and second extended ribs 124a and 124b limits fluid flow through gap between at least one of the respective first face 122c and the second face 122d of the housing 122 and the core 110 received in the housing 122.

In one embodiment, the extended ribs 124a are formed only on the first face 122 and extends from the first face 122c up to the top of the core 110 to limit fluid flow through gap between the first face 122c and the top of the core 110. In another embodiment, the extended ribs 124b are formed only on the second face 122d and extends from the second face 122d up to the bottom of the core 110 to limit fluid flow through gap between the second face 122d and the bottom of the core 110. In accordance with still another embodiment of the present invention, the extended ribs 124a are formed on the first face 122c and the extended ribs 124b are formed on the second face 122d. The extended ribs 124a extend from the first face 122c up to the top of the core 110 to limit fluid flow through gap between the first face 122c and the top of the core 110. Similarly, the extended ribs 124b extends from the second face 122d up to the bottom of the core 110 to limit fluid flow through gap between the second face 122d and the bottom of the core 110. The extended ribs 124a and 124b prevents leakage of the second heat exchange fluid, particularly, the coolant between the housing 122 and the core 110.

The first coolant flow passage 116a and the second coolant flow passage 116b disposed at extreme ends of the core 110 receive the at least one first fin 118a and at least one second fin 118b respectively. More specifically, the first coolant flow passage 116a receives one or more first fins 118a. Similarly, the second coolant flow passage 116b receives one or more second fins 118b. The centrally disposed coolant flow passage 116 receives the at least one fin 118. The at least one first fin 118a and the at least one second fin 118b is capable of being deformed to restrict coolant flow through the respective first coolant flow passage 116a and the second coolant flow passage 116b respectively. In accordance with an embodiment of the present invention, the at least one first fin 118a and the at least one second fin 118b are of same configuration and material as that of other fins 118 received in the centrally disposed coolant flow passages 116. In accordance with another embodiment of the present invention, the at least one first fin 118a and the at least one second fin 118b are of different configuration and material than that of other fins 118 received in the centrally disposed coolant flow passages 116. However, the present invention is not limited by whether the first and the second fins 118a and 118b are of same material and configuration as that of the other fins 118 received in the centrally disposed coolant flow passages 116 as far as the first and the second fins 118a, 118b are capable of being deformed to disrupt the flow through the corresponding first and second coolant flow passages 116a and 116b.

In accordance with an embodiment of the present invention, the at least one first fin 118a and the at least one second fin 118b are deformed before assembly between the housing 122 and the core 110. The at least one first fin 118a and the at least one second fin 118b can be deformed by using any method such as hammering, punching and forming. However, the present invention is not limited to any particular method for deforming the at least one first fin 118a and the at least one second fin 118b.

Alternatively, at least one of the first and the second extended ribs 124a and 124b interact with and deform at least one of the respective first fin 118a and the second fin 118b disposed in the respective first coolant flow passage 116a and the second fluid flow passage 116b disposed at extreme ends of the core 110. More specifically, multiple extended ribs 124a and 124b deform the at least one first fin 118a and the at least one second fin 118b respectively to at least partially disrupt the fluid flow through the first coolant flow passage 116a and the second fluid flow passage 116b respectively. In one embodiment, the extended ribs 124a interact with and deform the at least one first fin 118a disposed in the first coolant flow passage 116a to disrupt flow of the coolant through the first coolant flow passage 116a. In another embodiment, the extended ribs 124b interact with and deform the at least one second fin 118b disposed in the second coolant flow passage 116b to disrupt flow of the coolant through the second coolant flow passage 116b. In accordance with yet another embodiment of the present invention, the extended ribs 124a interact with and deform the at least one first fin 118a and the extended ribs 124b interact with and deform the at least one second fin 118b. The deformation of the at least one first fin 118a and the at least one second fin 118b at least partially disrupts flow through the respective first coolant flow passage 116a and second fluid flow passage 116b, thereby promoting flow through the centrally disposed flow passages 116 and improving efficiency and performance of the chiller 100. The at least one first fin 118a and the at least one second fin 118b can be deformed either before the assembly between the core 110 and the housing 122 or during the assembly between the core 110 and the housing 122. More specifically, either one of vibration welding, ultrasonic soldering, ultrasonic welding used to form joint between the first portion 122a and the second portion 122b causes the extended ribs 124a and 124b to interact with the corresponding first and second fins 118a and 118b, wherein interaction between the extended ribs 124a and 124b and the corresponding first and second fins 118a and 118b causes deformation of the first and the second fins 118a and 118b. However, present invention is not limited to whether deformation of the fins 118a, 118b happened before assembly or during assembly as along as the deformation of the first and the second fins 118a and 118b disrupted flow through the corresponding first and second coolant flow passages 116a and 116b. The chiller 100 further includes locating elements to ensure that the extended ribs 124a and 124b and the respective fins 118a and 118b are aligned with respect to each other and interact with each other during assembly between the housing 122 and the core 110, to cause the extended ribs 124a and 124b to deform the respective fins 118a and 118b.

More specifically, the extended ribs 124a extending from the first face 122c interact with and deform the corresponding at least one first fin 118a to not only form sealing between the first face 122c of the housing 122 and the top portion of the core 110 but also disrupt fluid flow through the respective first fluid flow passage 116a. Similarly, the extended ribs 124b extending from the second face 122d interact with and deform the corresponding at least one second fin 118b to not only form sealing between the second face 122d of the housing 122 and the bottom portion of the core 110 but also disrupt fluid flow through the respective second fluid flow passage 116b. The at least one first fin 118a and the at least one second fin 118b are of deformable material and are of such configuration that facilitates deformation thereof upon interaction with respective extended ribs 124a and 124b in the assembled configuration to prevent deformation of other elements of the core 110. The extended ribs 124a and 124b and the respective first and second fins 118a and 118b so contact with each other that forces exerted by the extended ribs 124a and 124b during assembly between the core 110 and the housing 122 are dissipated in deforming the respective first and second fins 118a and 118b. Accordingly, the forces exerted by the extended ribs 124a and 124b are prevented from being transmitted to and deforming the other elements of the core 110. The first and the second fins 118a and 118b are of such construction/thickness that the first and the second fins 118a and 118b undergo deformation when subjected to deforming forces by the respective extended ribs 124a and 124b. More specifically, the forces exerted by the extended ribs 124a and 124b only deform the first and the second fins 118a and 118b but not the other elements of the core 110 such as for example, the subsequent tubular elements 112a and 112b, the fins 118 received in the centrally disposed coolant flow passages 116.

Also, is disclosed a method 400 for assembling a heat exchanger, particularly, a chiller 100 in accordance with an embodiment of the present invention. FIG. 6 illustrates a block diagram depicting the various steps of the method 400 for assembling the chiller 100, particularly, the method 400 involves the step of receiving a core 110 inside either of complimentary portions 122a and 122b of a housing 122. Thereafter, supporting either one of the complimentary portions 122a and 122b with the core 110 received therein inside a holder 300. Thereafter, aligning and joining the complimentary portions 122a and 122b to form an assembled configuration of the core 110 and the housing 122. In the assembled configuration, the extended ribs 124a and 124b extend from a first face 122c and a second face 122d to the core 110 to form sealing between the core 110 and the housing 122. Further, in the assembled configuration, at least one of the extended ribs 124a and 124b deform at least one of the respective first fins 118a received in a first coolant flow passage 116a and second fins 118a received in a second coolant flow passage 116b. The deformation of at least one of the first fins 118a and the second fins 118b disrupts flow through at least one of the respective first coolant flow passage 116a and the second coolant flow passage 116b. Although, the various steps of the method 400 are depicted by blocks in the flow diagram and any number of steps described as method blocks can be combined in any order or can be performed in parallel to employ the method 400, or an alternative method. Additionally, individual blocks may be deleted from the flow chart depicting the method without departing from the scope and ambit of the present invention. The method 400 is to be understood with reference to the following description along with the Fig. 6.

The method 400 includes the step 402 of receiving at least a portion of the core 110 inside an enclosure defined by side-walls of either one of a top portion 122a and a bottom portion 122b of the housing 122. Thereafter, the method includes the step 404 of supporting either one of the top portion 122a and the bottom portion 122b of the housing 122 in an inverted configuration thereof along with the core 110 received therein inside a holder 300. Subsequently, the method includes the step 406 of aligning a portion of the housing 122 other than the one supported in the holder 300 with the portion of the housing 122 supported inside the holder 300 and joining the complimentary and aligned portions 122a and 122b of the housing 122 by either one of vibration welding, ultrasonic soldering, ultrasonic welding and using threaded fasteners to define an assembled configuration of the housing 122 and the core 110. In accordance with an embodiment of the present invention, the complimentary, aligned portions 122a and 122b of the housing 122 are pushed towards each other by synotrode and are subjected to vibration in frequency range of 20KHz for forming connection between the portions 122a and 122b of the housing 122. In the assembled configuration, at least one of extended ribs 124a and 124b extend from at least one of the first face 122c and the second face 122d to at least one of top and bottom of the core 110 to form sealing between the core 110 and the housing 122. Finally, the method includes the step 408 of deforming at least one of first fins 118a received in the first coolant flow passage 116a and second fins 118b received in the second coolant flow passage 116b of the core 110 either one of during assembly and before assembly to disrupt fluid flow through at least one of the respective first coolant flow passage 116a and the second coolant flow passage 116b.

Several modifications and improvement might be applied by the person skilled in the art to the heat exchanger, particularly, the chiller, as disclosed above and such modifications and improvements will still be considered within the scope and ambit of the present invention, as long as the heat exchanger includes a core and a housing. The core includes sets of tubular elements and a plurality of fluid flow passages. The sets of tubular elements are in fluid communication with a first pair of inlet and outlet to define first fluid flow there-though. The plurality of fluid flow passages are receiving fins therein. The plurality of fluid flow passages are in fluid communication with a second pair of inlet and outlet to define second fluid flow there-though. The fluid flow passages sandwich at least one set of tubular elements. The housing includes a first portion and a second portion assembled to form an enclosure and receive the core therein to define an assembled configuration of the core and the housing. The housing includes a plurality of ribs that extend from at least one of a first face and a second face of the housing respectively towards the core received in the housing. The ribs extending from at least one of the first face and the second face includes extended ribs that limit fluid flow through gap between the core received in the housing and at least one of the respective first face and the second face in the assembled configuration. At least one first fin and at least one second fin disposed in respective first and second fluid flow passages at extreme ends of the core are deformed to at least partially disrupt fluid flow through the respective first and second fluid flow passages.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.

In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.