Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
  • F28F9/0243—Header boxes having a circular cross-section
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
  • F28F9/0202—Header boxes having their inner space divided by partitions
  • F28F9/0204—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions
  • F28F9/0209—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions having only transversal partitions
  • F28F9/0212—Header boxes having their inner space divided by partitions for elongated header box, e.g. with transversal and longitudinal partitions having only transversal partitions the partitions being separate elements attached to header boxes
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
  • F28F9/00—Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
  • F28F9/02—Header boxes; End plates
  • F28F9/0219—Arrangements for sealing end plates into casing or header box; Header box sub-elements
  • F28F9/0224—Header boxes formed by sealing end plates into covers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F28—HEAT EXCHANGE IN GENERAL
  • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
  • F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
  • F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
  • F28D2021/008—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for vehicles
  • F28D2021/0084—Condensers

Definitions

• the present invention is directed to the field of manifold assemblies for use with heat exchangers, particularly heat exchangers for refrigeration applications.
• Heat exchangers for refrigeration applications are subjected to relatively high internal refrigerant pressure. Further, such heat exchangers cannot allow any leakage of refrigerant into the atmosphere and therefore preferably are designed with as few manufacturing connections as possible. Where manufacturing connections are necessary, their joints must be able to be manufactured economically and with a high probability that they will not leak.
• Automotive condensers have typically been constructed with a single length of refrigerant tube, assembled in a serpentine configuration with an inlet at one end and an outlet at the other end. In some cases, two or more of such serpentine coils are assembled into an intertwine configuration so as to provide a multiple path flow o refrigerant across the air flow. The ends of the separat serpentine coils are connected to common manifolds. Thi concept of multiple path flow is extended to what is called “parallel flow heat exchanger," in which all refrigerant tube are straight and parallel to each other with the individua ends of these tubes connected to respective inlet and outle manifolds. This configuration is commonly utilized in th construction of engine cooling radiators, oil coolers, an more recently, air conditioning condensers.
• R-134A chlorinated refrigerants
• the R-134A refrigerant is not as efficient as R-12 refrigerants, and also operates at higher pressure than R-12 refrigerants.
• the lower efficiency of the R-134A refrigerant requires a condenser design which not only is more efficient, such as a parallel flow design, but also is able to withstand higher internal operating pressures.
• Manifolding multiple tubes to withstand high interna pressure can best be accomplished with a tubular manifold, th cross-section of which is circular for highest strength.
• U.S patent No. 4,825,941 to Hoshino et al. is an example of suc a manifold with a circular cross-section.
• the chie disadvantage to the tubular manifold with a circular cross section is the difficulty of piercing the series of holes i each manifold to receive the multiple parallel refrigeran tubes.
• the tubular manifold with circular cross-sectio presents difficulties in assembly during manufacture. On partial solution to these problems is to flatten one side o each manifold tube as shown in Fig.
• a two-piec manifold comprising a tank and a header plate.
• the tank is formed with inwardly facing groove and the tank is slid into engagement with the header plate, which is planar.
• the tank can alternatively be formed with inwardly curved side wall members and the header plate can be formed with upturned longitudinal edges for gripping engagement with the side wall members of the tank when the tank is slid into engagement with the header plate.
• the tank is coated before assembly with a brazing material and flux to enable it to be secured upon assembly to the header plate.
• the tank is provided with a flange, tabs are placed on the header plate, a gasket is inserted between the header plate and the tank, and the tabs are crimped over the tank flange.
• a gasket is inserted between the header plate and the tank, and the tabs are crimped over the tank flange. Examples of such a construction are shown in U.S. patent No. 4,455,728 to Hesse, U.S. patent No. 4,531,578 to Stay et al., and U.S. patent No. 4,600,051 to Wehrman.
• a leak-type seal is provided by compressing the gasket. However, compression of the gasket is not sufficient to seal the header plate and tank under the high,pressures found in condensers.
• a pair of opposed, longitudinally-extending horizontal ribs can be formed in the inner wall of the tank and provided with opposed slots to receive baffles, in order to adjust the flow pattern.
• the horizontal ribs can also serve as tube stops.
• a manifold assembly which comprises a unitary tank having a substantially U-shaped cross-section and unitary header plate which has a substantially U-shaped semi-circular cross-section.
• the tank comprises an at least partially curved upp portion which in cross-section forms the base of the U, a pa of opposed sides extending from the ends of the upper porti and which in cross-section form the arms of the U, a pair opposed inner side walls, an inner upper wall intermediate t inner side walls, a pair of outer side walls, an outer upp wall intermediate the outer side walls, a pair of longitudin bottom edges extending between the inner and outer walls a the free ends of the sides, and a pair of longitudina channels formed in the bottom edges of the sides. Th channels divide the bottom edges into inner and oute portions.
• the header plate comprises an inner wall, an outer wall and a pair of upper edges intermediate the inner and oute wall which are matingly received in the channels formed in th bottom edges of the tank.
• a plurality of transverse tub holes are formed through the header plate along its cente line for receiving the tubes of the condenser or evaporator
• a flange or lip is formed around the tube holes t provide both a tube lead-in and a joint filleting pocket.
• Th inner portions of the bottom edges of the tank form stop against which the tubes abut.
• the tank and header plate ar brazed together along substantially the entire lengths o their mating surfaces in order to provide an exceptionall uniform and consistent brazed joint or fillet which provide the strength to withstand high internal pressures.
• the tank and header plate are formed of aluminum an aluminum alloy materials suitable for furnace brazing, a least one of the mating surfaces being fabricated with a lowe temperature clad brazing material, so that when the tank, header plate, and tubes are assembled, fixtured, and brazed i a high temperature brazing furnace, the clad material provide the brazed material to braze the tubes to the header plate an the header plate to the tank.
• the tank is formed by extrusion and the header plate is formed by stamping.
• the tank is extruded from an aluminum alloy such as AA3003 or the like
• the header plate is fabricated from sheet aluminum of a desired based aluminum alloy such as AA3003 or the like, clad on both surfaces with aluminum alloy such as 4004 or any other suitable brazing alloy.
• a plurality o opposed transverse slots can be formed through the tank an header plate along their center lines to receive baffle therein, in order to adjust the flow pattern.
• the baffles ar configured to engage the inner walls and sides of the slots and are also formed of aluminum and aluminum alloy material suitable for furnace brazing, so that when the manifol assembly is brazed in a high temperature brazing furnace, th baffles are brazed to the tank and the header plate.
• a bracket can b formed unitarily with one of the outer side walls of the tank.
• Figure 1 is a perspective view, partially cut away, of a manifold and heat exchanger assembly in accordance with the present invention.
• Figure 2 is an end view of the manifold a heat exchanger assembly of Figure 1.
• Figure 3 is a cross-sectional view of the manifold an heat exchanger assembly of Figure 1, taken along line 3-3 o Figure 1.
• Figure 4 is a cross-sectional view of the manifold an heat exchanger assembly in accordance with the presen invention, with the tank, header plate, and baffle unassembled.
• Manifold and heat exchanger assembly 100 comprises a manifold assembly 110 into which are inserted a plurality of parallel condenser or evaporator tubes 112.
• Manifold assembly 110 comprises a unitary tank 120 having a substantially U-shaped cross-section and a unitary header plate 150 having a substantially semi-circular cross-section.
• manifold assembly 110 has a substantially circular cross-section.
• the use of a curved cross-section for both tank 120 and header plate 150 enables manifold assembly 110 to withstand higher internal pressures than D-shaped manifold assemblies.
• Tank 120 comprises an at least partially curved upper portion 122 which in cross-section forms the base of the U, a pair of opposed sides 124 extending from the ends of upper portion 122 and which in cross-section form the arms of the U, a pair of opposed inner side walls 130, an inner upper wall 132 intermediate inner side walls 130, a pair of outer side walls 140, an outer upper wall 142 intermediate outer side walls 140, and a pair of longitudinal bottom edges 144 extending between inner and outer side walls 130 and 140 at the free ends of sides 124.
• inner side walls 130 are substantially planar and parallel to each other, while one of outer side walls 140 is curved and the other is unitaril provided with a mounting bracket 140a.
• Inner upper wall 132 is also curved.
• Outer upper wall 142 is formed with substantially planar, central longitudinal rib 142a.
• a pair of longitudinal channels 146 are formed in bottom edges 144. Channels 146 divide bottom edges 144 into inner and outer portions 144a and 144b.
• Header plate 150 has a length substantially equal to the length of tank 120 and comprises an inner wall 152, an outer wall 154 substantially parallel to inner wall 152, and a pair of longitudinal upper edges 160 extending between inner and outer walls 152 and 154.
• Inner wall 152 includes a pair of opposed . inner side walls 162 and an inner lower wall 164 intermediate inner side walls 162.
• a plurality of transverse tube holes 170 are formed through header plate 150 along its longitudinal center line for receiving tubes 112 of manifold and heat exchanger assembly 100.
• Flanges or lips 172 are formed around tube holes 170.
• Flanges 172 are very uniform formed sections which follow the internal contour of header plate 150, i.e. the contour in inner wall 152, thereby providing both a tube lead-in and a joint filleting pocket.
• Tank 120 preferably is formed by extrusion. Header plate 150 preferably is formed by stamping. Tank 120 can be extruded from an aluminum alloy such as AA3003 or the like, while header plate 150 is fabricated from sheet aluminum of a desired base aluminum alloy such as AA3003 'or the like, clad on both surfaces with aluminum alloy such as 4004, or other suitable brazing alloys.
• Aluminum alloy such as AA3003 or the like
• header plate 150 is fabricated from sheet aluminum of a desired base aluminum alloy such as AA3003 'or the like, clad on both surfaces with aluminum alloy such as 4004, or other suitable brazing alloys.
• a plurality of opposed transverse slots 180 can be formed through tank 120 and header plate 150 along their longitudinal center lines to receive baffles 190 therein, in order to adjust the flow pattern.
• Baffles 190 are configured to form a tight fit with inner side walls 130 of tank 120 and inner side walls 162 of header plate 150, and to extend outwardly of outer upper wall 142 of tank 120 and outer wall 154 of header plate 150.
• Inner portions 144a of bottom edges 144 of tank 120 extend inwardly a sufficient amount to act as stops for tubes 112.
• Inner side and upper walls 130 and 132 of tank 120 can be coated with clad alloy in order to braze baffles 190 to inner wall 130.
• Tank 120 is assembled to header plate 150 by inserting upper edges 160 of header plate 150 into channels 146. This form of assembly permits a close fit between the abutting surfaces of tank 120 and header plate 150, resulting in effective brazing. Further, it allows the filler material or alloy to flow freely to provide a uniform and consistent brazed joint or fillet. Tubes 112 are assembled to head plate 150 through header flanges 172 with their ends abutti inner portions 144a of bottom edges 144 of tank 120.
• Assembly of tank 120 with baffles 190 and header pla 150 can also be accomplished as a unit prior to assembly manifold assembly 110 to tubes 112. Where, in certain brazi operations it is desired to use flux, the flux can be appli to the mating surfaces of the parts before their assembl The prior art makes this operation very difficult.
• baffles 190 either before assembly o tank 120 and header plate 150 or through slots 180 afte assembly of tank 120 and header plate 150.
• tank 120, header plate 150, and baffles 18 are formed of aluminum and aluminum alloy materials suitabl for brazing, at least one of the mating surfaces bein fabricated with a lower temperature clad brazing material.
• a lower cost extruded alloy can be used for tan 120, while a clad brazing sheet can be used for header plat 150.
• a clad brazing sheet can be used for header plat 150.
• the clad material on heade plate 150 provides the brazed material to braze tubes 112 to header plate 150, header plate 150 to tank 120, and baffles 190 to tank 120 and header plate 150.
• the pocket provided by header flanges 172 allows the braze to form a uniform fillet on flanges 172, which in turn allows a uniform tube-to-header fillet during braze.

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• Engineering & Computer Science (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
• Details Of Heat-Exchange And Heat-Transfer (AREA)

Applications Claiming Priority (3)

Publications (3)

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Cited By (2)

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• 1992
  • 1992-08-21 JP JP5504471A patent/JPH06508915A/ja active Pending
  • 1992-08-21 EP EP92918281A patent/EP0599972B1/de not_active Expired - Lifetime
  • 1992-08-21 DE DE69215098T patent/DE69215098T2/de not_active Expired - Fee Related
  • 1992-08-21 WO PCT/US1992/006853 patent/WO1993004334A1/en active IP Right Grant
  • 1992-08-21 ES ES92918281T patent/ES2093843T3/es not_active Expired - Lifetime
  • 1992-08-21 CA CA002116352A patent/CA2116352A1/en not_active Abandoned
  • 1992-08-21 AU AU24902/92A patent/AU2490292A/en not_active Abandoned
  • 1992-08-21 AT AT92918281T patent/ATE145053T1/de not_active IP Right Cessation

Non-Patent Citations (2)

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