This disclosure details exemplary battery pack designs for use in electrified vehicles or other electrified components. An exemplary battery pack may include a heat exchanger plate assembly having a metallic plate and a polymeric plate that are joined together to establish a coolant circuit therebetween. The metallic plate or the polymeric plate may include a protrusion that extends through an opening of the other of the metallic plate or the polymeric plate. The protrusion may either be crimped or heat staked to a surface surrounding the opening in order to join together the metallic plate and the polymeric plate of the heat exchanger plate assembly.

A heat exchanger includes a duct, a core portion, and a caulking plate. The duct has an inlet and an outlet. The core portion is housed in the duct in a state where cooling plates and cooling fins are stacked in a stacking direction. The caulking plate has a frame shape corresponding to an opening shape of the inlet and the outlet and brazed to the inlet and the outlet. The caulking plate is interposed between the duct and a tank to fix the tank. A first joint between the duct and the core portion and a second joint between the duct and the caulking plate are distanced from each other in the stacking direction by a predetermined distance. The duct has a rib between the first joint and the second joint or at the second joint.

A crimping frame or crimping base for a charge air cooler may include a circumferential raised rim including a plurality of crimping slots. The plurality of crimping slots may each include two longitudinal sides and two narrow sides. The two longitudinal sides may be disposed opposite one another and may extend parallel to the rim. The two narrow sides may be stiffened via a bent reinforcement. The bent reinforcement and the rim may be structured as a single piece.

A method and system are described for a refrigerant distributor, and for attaching the distributor tubes to an evaporator coil. A short tube can inserted into the bell end of a tube and the hell end can he crimped around the short tube to lock it into place. The short tube preferably has a bead or widened shaft around which to crimp the bell. The disclosure is particularly beneficial for aluminum based components because aluminum is more susceptible to blockages or leaking due to problems from brazing.

A thermal module assembling structure includes a heat dissipation board and at least one heat pipe. The heat dissipation board has a receiving channel for fitting the heat pipe therethrough. Two sides of upper side of the receiving channel are respectively formed with two ribs. The ribs horizontally protrude and extend toward the middle of the receiving channel to face the heat pipe fitted in the receiving channel. At least one deformed recess is formed on an upper surface of each of the ribs, whereby the lower surfaces of the ribs and a surface of the heat pipe are deformed to form at least one deformed connection section between the lower surfaces of the ribs and the surface of the heat pipe. By means of the restriction of the deformed connection section, the heat pipe is prevented from being extracted out of the receiving channel.

A helical heat exchanger assembly comprises a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter, and a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis. The tube insert is sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube, respectively. A plurality of inlet and outlet fluid ports are positioned for passage of a first and second fluid into and out of the tube. The helix has a predetermined pitch which may be less than or greater than the tube inner diameter and defines a length of the first and second fluid flow paths, wherein the pitch of the helix may be constant or variable along the length of the tube insert.

A heat exchanger includes a duct, a core accommodated in the duct and exchanging heat between a first fluid and a second fluid, a tank having a protrusion protruding outward from an edge portion, and a crimping plate. The crimping plate includes an opposing wall facing an edge of the tank adjacent to the duct, and an outer wall extending from an outer circumference of the opposing wall. The opposing wall or an inner circumference of the opposing wall is joined to the duct and fixes the tank. The protrusion includes a surface facing in a direction angled toward the inner space from a direction in which the outer wall extends from the opposing wall.

A high-efficiency heat sink includes a base and a plurality of heat sink fins A folded portion of each heat sink fin is formed by folding after being pressed and thinned, so that the thickness of the folded portion is less than the thickness of an insertion end of each heat sink fin. The thickness of the portion where the heat sink fin is inserted into a groove of the base is less than twice the thickness of the heat sink fin. It is beneficial to reduce the distance between two adjacent heat sink fins on the base, so that the heat sink fins can be arranged more densely, thereby improving the heat dissipation effect of the entire heat sink effectively.

Provided are a housing assembly and a water heater. The housing assembly includes a bottom plate assembly and an outer housing. The outer housing is provided with a hooking fitting portion, the bottom plate assembly includes: a base and a supporting portion, a crimping space for positioning the outer housing is formed between at least portion of the supporting portion and the base. The hooking fitting portion is hooked with the crimping space.

A heat exchanger includes tube expansion portions provided respectively on a plurality of heat transfer tubes such that outer peripheral surfaces of the heat transfer tubes are respectively pressed against inner peripheral surfaces of a plurality of first holes provided in a side wall portion of a case, and a plurality of first concave surface portions provided in an outer surface of the tube expansion portion so that first gaps, into which brazing material of a first brazed portion advances, are formed between the outer surface of the tube expansion portion and the inner peripheral surface of the first hole. At least one of the plurality of first concave surface portions is positioned in an outside peripheral surface portion of the outer peripheral surface of the heat transfer tube. According to this configuration, the strength with which the heat transfer tubes are attached to the case can be increased while simplifying a manufacturing operation and reducing the manufacturing cost.