EP2017563B1 - Header plate and method of manufacture thereof - Google Patents

Header plate and method of manufacture thereof Download PDF

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Publication number
EP2017563B1
EP2017563B1 EP07112627A EP07112627A EP2017563B1 EP 2017563 B1 EP2017563 B1 EP 2017563B1 EP 07112627 A EP07112627 A EP 07112627A EP 07112627 A EP07112627 A EP 07112627A EP 2017563 B1 EP2017563 B1 EP 2017563B1
Authority
EP
European Patent Office
Prior art keywords
flaps
header plate
pair
header
end walls
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP07112627A
Other languages
German (de)
French (fr)
Other versions
EP2017563A1 (en
Inventor
Marek Filipiak
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
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Filing date
Publication date
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Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Priority to DE602007002562T priority Critical patent/DE602007002562D1/en
Priority to AT07112627T priority patent/ATE443840T1/en
Priority to EP07112627A priority patent/EP2017563B1/en
Publication of EP2017563A1 publication Critical patent/EP2017563A1/en
Application granted granted Critical
Publication of EP2017563B1 publication Critical patent/EP2017563B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • F28F9/04—Arrangements for sealing elements into header boxes or end plates
    • F28F9/16—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling
    • F28F9/18—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding
    • F28F9/182—Arrangements for sealing elements into header boxes or end plates by permanent joints, e.g. by rolling by welding the heat-exchange conduits having ends with a particular shape, e.g. deformed; the heat-exchange conduits or end plates having supplementary joining means, e.g. abutments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • 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
    • 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
    • F28F9/0226—Header boxes formed by sealing end plates into covers with resilient gaskets

Definitions

  • the present invention relates to a header plate for a heat exchanger, particularly, but not exclusively a header plate for use in a heat exchanger of an automobile.
  • a method of manufacturing the header plate is also provided.
  • Heat exchangers with flat sided tubes are widely used in various automotive applications. Typically, these tubes are inserted into pressed out slots S (see Fig. 1 ) on the header plate P of the heat exchanger. The tubes are then brazed or soldered to the header plate to provide a strong fluid tight connection there between.
  • the tubes are often brazed or soldered to the header plate at the same time as the header plate is brazed or soldered to the header tank.
  • the tubes are typically brazed to the header plate first and then the plastic tank is subsequently crimped to the header plate.
  • a significant depth component (indicated by D on Fig. 1 and Fig. 2 ) of the header plate P is needed to form the required connection. Therefore a problem with each of the presently available arrangements is that they occupy more space than is desired.
  • Another problem is that, in the present system, the relatively small contact area between the tubes and header plates can result in weakness of the joint which can lead to premature malfunction of the heat exchanger.
  • a heat exchanger header plate having oval tube receiving slots is described in United States Patent No. 5,390,519 , which discloses the preamble of claims 1 and 6.
  • a header plate for a heat exchanger comprising a base plate having a plurality of tube receiving slots formed therein, wherein at least one tube receiving slot comprises at least a pair of flaps and at least a pair of end walls folded toward said flaps characterised in that the flaps are rectangular flaps cut laterally into the tube receiving slot along the centre of the desired resultant tube receiving slot and which have a pair of short longitudinal cuts at each end of the rectangular flaps and which are folded away from the base plate and wherein the end walls have a lateral dimension large enough to form side walls of the header plate and are folded into contact with the rectangular flaps and wherein the contact between the side walls and the rectangular flaps allows brazing of the side walls to the rectangular flaps.
  • a method of manufacturing a header plate for a heat exchanger comprising providing a base plate, forming at least a pair of flaps in the base plate by making a plurality of cuts in the base plate, folding the flaps away from the base plate, folding at least a pair of end walls toward the flaps to thereby form a plurality of tube receiving slots characterised in that the step of forming the flaps comprises cutting laterally along the centre of the tube receiving slots and cutting short longitudinal cuts at each end of the desired resultant slot to form a pair of rectangular flaps and the method further includes the steps of folding the end walls into contact with the rectangular flaps and brazing the side walls to the rectangular flaps.
  • tube receiving slots refers to those known in the art and those with which the present invention is concerned and may include a mixture of both.
  • flaps could also consist of pair of end walls.
  • header plate 10 comprises a base plate having a number of pairs of flaps 1 cut and folded out there from.
  • the flaps are created by cutting laterally along the centre of the desired resultant slot and raising the pair of flaps 1 away from the header plate material.
  • a pair of short longitudinal cuts are also created at each end of flaps to allow them to be folded out more easily.
  • the header plate 10 will be in the form illustrated by Fig. 3 .
  • the length of the flaps 1 is such that border portions of the base plate defined by dashed lines 2 remain on either side of the flaps 1.
  • the border portions are folded along the dashed lines 2 until metal to metal contact occurs at a point 4 between the ends of the flaps 1 and the newly created end walls 3. This ensures that the subsequent soldering or brazing process provides good metallurgical contact. The result is a strong and leak free joint.
  • the completed header plate 10 is illustrated by Fig. 4 .
  • the flaps 1 provide tube receiving slots having a large area for contacting the flat sides of typical rectangular section heat exchanger tubes. This increased contact area and support significantly strengthens the resulting connection between the tubes and slots once brazing / soldering has been completed.
  • Another advantage is that a packaging reduction is achieved since the header plate of the present invention projects no further than a single sheet thickness from the front of the header tank. Such a packaging reduction is important in the automotive industry.
  • the tank can be completed in a variety of different ways.
  • the end walls 3 of the header plate 10 can be formed to be high enough to allow a capping section 12 to be bent round to seal off the top and ends of the tubes.
  • the side walls 3A can also be made tall enough to provide large depth tanks ( Fig. 6 ) or indeed tall enough to allow them to be folded around and welded together at either end 14 to form the header tank itself ( Fig. 7 ).
  • bracing members (not shown) between the walls and / or strengthening ribs 16 pressed into the surface of the walls.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
  • Tubes (AREA)
  • Making Paper Articles (AREA)
  • Rigid Pipes And Flexible Pipes (AREA)

Abstract

The invention relates to a header plate (10) which has a base plate formed with a series of tube receiving slots formed therein. The tube receiving slots each have a pair of lateral walls (3) cut and folded away from the base plate, and a pair of longitudinal walls folded away from the plane of the base plate. The combined effect of these folded out sections is a series of tube receiving slots which have a greater contact area to improve the resulting connection formed by subsequent solder/brazing. The resulting header plate also requires less packaging space. A method of manufacturing a header plate is also provided.

Description

  • The present invention relates to a header plate for a heat exchanger, particularly, but not exclusively a header plate for use in a heat exchanger of an automobile. A method of manufacturing the header plate is also provided.
  • Heat exchangers with flat sided tubes are widely used in various automotive applications. Typically, these tubes are inserted into pressed out slots S (see Fig. 1) on the header plate P of the heat exchanger. The tubes are then brazed or soldered to the header plate to provide a strong fluid tight connection there between.
  • Where the header tank is formed from metal, the tubes are often brazed or soldered to the header plate at the same time as the header plate is brazed or soldered to the header tank. Referring to Fig. 2, where the header tank T is formed from plastic, the tubes are typically brazed to the header plate first and then the plastic tank is subsequently crimped to the header plate. In either case, a significant depth component (indicated by D on Fig. 1 and Fig. 2) of the header plate P is needed to form the required connection. Therefore a problem with each of the presently available arrangements is that they occupy more space than is desired. Another problem is that, in the present system, the relatively small contact area between the tubes and header plates can result in weakness of the joint which can lead to premature malfunction of the heat exchanger.
  • A heat exchanger header plate having oval tube receiving slots is described in United States Patent No. 5,390,519 , which discloses the preamble of claims 1 and 6.
  • According to a first aspect of the present invention there is provided a header plate for a heat exchanger, the header plate comprising a base plate having a plurality of tube receiving slots formed therein, wherein at least one tube receiving slot comprises at least a pair of flaps and at least a pair of end walls folded toward said flaps characterised in that the flaps are rectangular flaps cut laterally into the tube receiving slot along the centre of the desired resultant tube receiving slot and which have a pair of short longitudinal cuts at each end of the rectangular flaps and which are folded away from the base plate and wherein the end walls have a lateral dimension large enough to form side walls of the header plate and are folded into contact with the rectangular flaps and wherein the contact between the side walls and the rectangular flaps allows brazing of the side walls to the rectangular flaps.
  • According to a second aspect of the present invention there is provided a method of manufacturing a header plate for a heat exchanger, the method comprising providing a base plate, forming at least a pair of flaps in the base plate by making a plurality of cuts in the base plate, folding the flaps away from the base plate, folding at least a pair of end walls toward the flaps to thereby form a plurality of tube receiving slots characterised in that the step of forming the flaps comprises cutting laterally along the centre of the tube receiving slots and cutting short longitudinal cuts at each end of the desired resultant slot to form a pair of rectangular flaps and the method further includes the steps of folding the end walls into contact with the rectangular flaps and brazing the side walls to the rectangular flaps.
  • Preferred features and advantages of the invention will be apparent from the following description and the claims.
  • Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, in which:-
    • Fig. 1 is a perspective view of a prior art header plate which has pressed out slots for connection to heat exchanger tubes;
    • Fig. 2 is a plan view of a prior art plastic header tank crimped to a prior art header plate;
    • Fig. 3 is a perspective view of a base plate of a header plate in a first stage of manufacture in accordance with first and second aspects of the present invention;
    • Fig. 4 is a perspective view of a base plate of the header plate of Fig. 3 in a second stage of manufacture;
    • Fig. 5 is a perspective schematic view of a capped section of a header plate mounted over the ends of heat exchanger tubes according to the prior art;
    • Fig. 6 is a perspective view of the inside of an example of a header plate according to the prior art where the plate is formed with tall sided header tank walls; and
    • Fig. 7 is a schematic planar view of a header plate of a further alternative embodiment, where the walls of the header plate are extended to allow them to be folded, closed upon one another and welded together to form an integrated header tank and header plate.
  • In the following it should be noted that the term tube receiving slots refers to those known in the art and those with which the present invention is concerned and may include a mixture of both. Furthermore, flaps could also consist of pair of end walls.
  • With reference to Figs. 3 and 4, header plate 10 comprises a base plate having a number of pairs of flaps 1 cut and folded out there from. The flaps are created by cutting laterally along the centre of the desired resultant slot and raising the pair of flaps 1 away from the header plate material. A pair of short longitudinal cuts are also created at each end of flaps to allow them to be folded out more easily. At this stage the header plate 10 will be in the form illustrated by Fig. 3. The length of the flaps 1 is such that border portions of the base plate defined by dashed lines 2 remain on either side of the flaps 1.
  • To form the desired tube receiving slots, the border portions are folded along the dashed lines 2 until metal to metal contact occurs at a point 4 between the ends of the flaps 1 and the newly created end walls 3. This ensures that the subsequent soldering or brazing process provides good metallurgical contact. The result is a strong and leak free joint. The completed header plate 10 is illustrated by Fig. 4.
  • The flaps 1 provide tube receiving slots having a large area for contacting the flat sides of typical rectangular section heat exchanger tubes. This increased contact area and support significantly strengthens the resulting connection between the tubes and slots once brazing / soldering has been completed.
  • Another advantage is that a packaging reduction is achieved since the header plate of the present invention projects no further than a single sheet thickness from the front of the header tank. Such a packaging reduction is important in the automotive industry.
  • The tank can be completed in a variety of different ways. For example, referring to Fig. 5, the end walls 3 of the header plate 10 can be formed to be high enough to allow a capping section 12 to be bent round to seal off the top and ends of the tubes.
  • The side walls 3A can also be made tall enough to provide large depth tanks (Fig. 6) or indeed tall enough to allow them to be folded around and welded together at either end 14 to form the header tank itself (Fig. 7).
  • With such high walls, it may be necessary to provide bracing members (not shown) between the walls and / or strengthening ribs 16 pressed into the surface of the walls.
  • Modifications and improvement may be made to the foregoing, without departing from the scope of the invention, for example, rather than folding out the flaps 1 from the base plate first and then folding up the side walls 3, the sequence of these operations could be either performed simultaneously or could indeed be reversed.
  • Furthermore, although the invention has been described in relation to an automobile heat exchanger, it could equally be applied to any heat exchanger.

Claims (10)

  1. A header plate for a heat exchanger, the header plate comprising a base plate having a plurality of tube receiving slots formed therein, wherein at least one tube receiving slot comprises at least a pair of flaps (1) and at least a pair of end walls folded toward said flaps (1) characterised in that the flaps are rectangular flaps (1) cut laterally into the tube receiving slot along the centre of the desired resultant tube receiving slot and which have a pair of short longitudinal cuts at each end of the rectangular flaps (1) and which are folded away from the base plate and wherein the end walls have a lateral dimension large enough to form side walls (3) of the header plate and are folded into contact with the rectangular flaps (1) and wherein the contact between the side walls (3) and the rectangular flaps (1) allows brazing of the side walls (3) to the rectangular flaps (1).
  2. A header plate according to claim 1, wherein the edges of the pair of end walls (3) are joined to one another.
  3. A header plate according to either of claims 1 or 2, wherein the pair of end walls (3) are provided with at least one of bracing members and strengthening ribs.
  4. A header plate according to any preceding claim, wherein the pair of end walls (3) are adapted to allow a capping section (12) to be formed by bending a portion thereof over the ends of the tubes of a heat exchanger.
  5. A heat exchanger header tank comprising a header plate according to claim 1.
  6. A method of manufacturing a header plate for a heat exchanger, the method comprising providing a base plate, forming at least a pair of flaps (1) in the base plate by making a plurality of cuts in the base plate, folding the flaps (1) away from the base plate, folding at least a pair of end walls (3) toward the flaps (1) to thereby form a plurality of tube receiving slots characterised in that the step of forming the flaps (1) comprises cutting laterally along the centre of the tube receiving slots and cutting short longitudinal cuts at each end of the desired resultant slot to form a pair of rectangular flaps (1) and the method further includes the steps of folding the end walls (3) into contact with the rectangular flaps (1) and brazing the side walls (3) to the rectangular flaps (1).
  7. A method of manufacturing a header plate according to claim 6, wherein the step of folding the pair of end walls (3A) also includes the step of joining them to one another.
  8. A method of manufacturing a header plate according to either of claims 6 or 7, further comprising the step of folding a portion of the header plate around tubes of a heat exchanger to form a capping section (12).
  9. A method of manufacturing a header plate according to any of claims 6 to 8 further comprising forming at least one of bracing members and strengthening ribs in the pair of end walls (3).
  10. A method of manufacturing a heat exchanger header tank, comprising the step of manufacturing a header plate according to the method of claim 6.
EP07112627A 2007-07-17 2007-07-17 Header plate and method of manufacture thereof Not-in-force EP2017563B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
DE602007002562T DE602007002562D1 (en) 2007-07-17 2007-07-17 Tube bottom and manufacturing method for it
AT07112627T ATE443840T1 (en) 2007-07-17 2007-07-17 TUBE SHEET AND PRODUCTION PROCESS THEREOF
EP07112627A EP2017563B1 (en) 2007-07-17 2007-07-17 Header plate and method of manufacture thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP07112627A EP2017563B1 (en) 2007-07-17 2007-07-17 Header plate and method of manufacture thereof

Publications (2)

Publication Number Publication Date
EP2017563A1 EP2017563A1 (en) 2009-01-21
EP2017563B1 true EP2017563B1 (en) 2009-09-23

Family

ID=38922766

Family Applications (1)

Application Number Title Priority Date Filing Date
EP07112627A Not-in-force EP2017563B1 (en) 2007-07-17 2007-07-17 Header plate and method of manufacture thereof

Country Status (3)

Country Link
EP (1) EP2017563B1 (en)
AT (1) ATE443840T1 (en)
DE (1) DE602007002562D1 (en)

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5390519A (en) * 1992-11-27 1995-02-21 Nippondenso Co., Ltd. Method for manufacturing long products by press working

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5794692A (en) * 1993-10-28 1998-08-18 Modine Manufacturing Co. Header and tank construction for a heat exchanger
JP3624486B2 (en) * 1994-12-20 2005-03-02 株式会社デンソー Heat exchanger and its manufacturing method
DE19605108A1 (en) * 1995-09-26 1997-03-27 Lingemann Helmut Gmbh & Co Collector tube for heat exchanger
JP3880098B2 (en) * 1996-03-27 2007-02-14 昭和電工株式会社 Heat exchanger and header pipe manufacturing method
FR2860289B1 (en) * 2003-09-26 2017-10-20 Valeo Thermique Moteur Sa HEAT EXCHANGER OF SHAPED SHAPE AND METHOD FOR MANUFACTURING THE SAME

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5390519A (en) * 1992-11-27 1995-02-21 Nippondenso Co., Ltd. Method for manufacturing long products by press working

Also Published As

Publication number Publication date
DE602007002562D1 (en) 2009-11-05
ATE443840T1 (en) 2009-10-15
EP2017563A1 (en) 2009-01-21

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