US20060118287A1 - Heat exchanger and method of making same - Google Patents
Heat exchanger and method of making same Download PDFInfo
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- US20060118287A1 US20060118287A1 US11/293,572 US29357205A US2006118287A1 US 20060118287 A1 US20060118287 A1 US 20060118287A1 US 29357205 A US29357205 A US 29357205A US 2006118287 A1 US2006118287 A1 US 2006118287A1
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- baffle
- tool
- header tank
- tube
- header
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Images
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
- F28F9/0246—Arrangements for connecting header boxes with flow lines
- F28F9/0248—Arrangements for sealing connectors 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
- F28F9/0202—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
- F28F9/0243—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
- F28F9/0246—Arrangements for connecting header boxes with flow lines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2220/00—Closure means, e.g. end caps on header boxes or plugs on conduits
Definitions
- This application generally relates to heat exchangers and more particularly relates to heat exchangers that incorporate internal baffles for directing fluid flow in the heat exchanger.
- typical heat exchangers 100 include a core assembly 102 positioned between an upper 106 and lower 108 header tank.
- Core assembly 102 is traditionally comprised of alternating layers of cooling tubes 104 and fins 105 . It is typical for fins 105 to be formed in a serpentine shape and to be fastened, at numerous contact points, to two adjacent cooling tubes.
- Each cooling tube 104 extends between spaced header tanks 106 , 108 and through a side wall of spaced header tanks 106 , 108 . The ends of each of the tubes 104 extend to the header tanks 106 , 108 and are sealed thereto typically by furnace brazing or the like.
- a first fluid flows from one header tank 106 , 108 to the other header tank 106 , 108 by way of a center passageway within each cooling tube 104 .
- a second fluid typically ambient air, passes over an outside surface of the cooling tubes 104 and the fins 106 . If the second fluid has a lower temperature than the first fluid, the fluid in the heat exchanger 100 will be cooled as it flows between header tanks 106 , 108 .
- header tanks 106 , 108 In many applications, it is desirable to divide one or more of the header tanks 106 , 108 into a plurality of chambers. Although a number of techniques are well-known for doing so, they all involve complex tooling, or labor intensive techniques.
- the present invention sets forth various systems and methods for compartmentalizing header tanks 106 , 108 of heat exchangers 100 .
- the present invention also sets forth numerous structures for attaching ancillary hardware to heat exchangers.
- FIG. 1 is a prior art heat exchanger
- FIG. 2 is a partial cross sectional view of an embodiment of a heat exchanger of the present invention
- FIG. 3 is a partial exploded view of the header tank and supporting components found within encircled portion 3 of FIG. 2 ;
- FIG. 4 is an assembled view of the components of FIG. 3 ;
- FIG. 5A-5J are various embodiments of a baffle and baffle/tube assemblies of the present invention.
- FIG. 6 is a partial cross sectional view of an end portion of a header tank employing a baffle and a rubber isolator to mount a heat exchanger to an adjacent support structure;
- FIG. 7 is a partial cross sectional view of a pass through baffle joined to a header tank
- FIG. 8 is a partial cross sectional view of a header tank employing a stop baffle and a pass through baffle wherein the pass through baffle engages an inlet/outlet tubular member to provide strain relief to the inlet/outlet tubular member;
- FIG. 9 is a partial cross sectional view of a stop baffle and a pass through baffle wherein both the stop baffle and the pass through baffle perform a strain relief function for an inlet/outlet member;
- FIG. 10 is a partial exploded view of a header tank, a saddle coupling, and an I/O member wherein the saddle coupling employs an integrated baffle;
- FIG. 11 is a partial cross sectional view taken substantially through lines 11 - 11 of FIG. 10 ;
- FIG. 12 is a partial cross sectional view taken substantially along lines 12 - 12 of FIG. 10 ;
- FIG. 13 is a partial cross sectional view showing a header tank employing a stop baffle as a terminal end cap for the header tank;
- FIG. 14 is a partial cross sectional view showing a header tank employing a standard radiator cap connector at a terminal end of the header tank;
- FIG. 15 is a partial cross sectional view showing a joint between a header tank and a tabbed portion of a structural side member
- FIG. 16 is a partial cross sectional view showing a method of attaching a structural side member to a header tank by displacing material from the structural side member;
- FIG. 17 is a partial cross sectional view of first and second heat exchangers wherein the header tanks of the respectively associated first and second heat exchangers are joined using mating members;
- FIG. 18A is a side elevational view of a first and second heat exchanger assembly employing a connector plate to join the first and second heat exchangers along an end portion of their respectively associated header tanks.
- FIG. 18B is a side elevational view of a first and second heat exchanger assembly employing a common side support member.
- FIG. 19 is a partial cross sectional view taken substantially along lines 19 - 19 of FIG. 18 .
- FIG. 20 is a partial cross sectional view of an embodiment of a high pressure manifold connected to a baffle.
- FIG. 21 is a partial cross sectional view of yet another embodiment of a high pressure manifold connected to a baffle.
- FIG. 22A is a depiction of a pierce tool aligned with a work piece to be operated on by the pierce tool.
- FIG. 22B is a depiction of a pierce tool after it has worked upon a work piece.
- FIG. 22C is a side elevational view of the pierce tool of FIG. 22A .
- FIG. 23A is a front elevational view of a tool having a piercing portion that includes a concave side profile.
- FIG. 23B is a side elevational view of the tool of FIG. 23A .
- FIG. 24A is a front elevational view of a tool having a profile with generally linearly tapered sides.
- FIG. 24B is a side elevational view of a tool of FIG. 24A .
- FIG. 25 is a side elevational view of a pierce tool which has pierced through a work piece while the work piece has an inner chamber which is exposed to pressurized fluid.
- FIG. 26 is a pierce tool which has pierced through a work piece while an inner chamber of the work piece is exposed to atmospheric pressure.
- FIG. 27 is a partial cross sectional view of a bell mouth opening created in a side wall of a work piece.
- FIG. 28 is a partial cross sectional view of a bell mouth opening which has been formed by a pierce operation through the side wall of a work piece wherein the bell mouth opening has been threaded to accept a threaded fastener.
- FIG. 29 is an assembly showing multiple pierce tools affixed to a tool base.
- FIG. 30 is a front elevational view of a piercing apparatus used to pierce multiple slots in a work piece.
- FIG. 31 is a partial cross sectional view taken substantially through lines 31 - 31 of FIG. 30 .
- FIG. 32 is the apparatus of FIG. 30 shown in an intermediate, descending position.
- FIG. 33 is a partial cross sectional view taken substantially through lines 33 - 33 of FIG. 32 .
- FIG. 34 is the apparatus of FIG. 30 shown in a position just prior to pierce tools piercing a work piece.
- FIG. 35 is a partial cross sectional view taken substantially through lines 35 - 35 of FIG. 34 .
- FIG. 36 is an enlarged view of a plunger assembly and associated components shown substantially within encircled portion 36 of FIG. 34 .
- FIG. 37 is the apparatus of FIG. 30 wherein pierce tools are positioned in the lower most portion of their downward stroke.
- FIG. 38 is a partial cross sectional view taken substantially through lines 38 - 38 of FIG. 37 .
- FIG. 39 is an enlarged view of the plunger assembly and related components found within encircled portion 39 of FIG. 37 .
- FIG. 40 is a partial cross sectional view of another embodiment of a piercing apparatus having both upper piercing tools and lower piercing tools.
- heat exchanger 200 includes upper header tank 206 , lower header tank 208 and a plurality of cooling tubes 204 that communicate a fluid between upper header tank 206 and lower header tank 208 .
- a structural side member 210 can, optionally, be used to bind upper header tank 206 to lower header tank 208 thereby giving the entire assembly greater mechanical strength than that which may be present if cooling tubes 204 were the sole means of tying upper header tank 206 to lower header tank 208 .
- Optional structural side member 210 can be fastened to upper header tank 206 and lower header tank in any number of ways known to those skilled in the art.
- member 210 can be brazed to an outer surface of the header tanks 206 , 208 , it can be mechanically fastened to the header tanks using mechanical fasteners (such as screws and the like) or, as is shown in FIG. 2 , it can be received within an opening in a sidewall portion of header tanks 206 , 208 and thereafter it can be fastened (e.g. furnace brazed) in place.
- mechanical fasteners such as screws and the like
- a rubber isolator or the like 212 , 214 may be used to structurally mount heat exchanger 200 to an adjacent support structure 216 .
- Rubber isolator 212 , 214 not only acts as the means for transferring load from heat exchanger 200 to adjacent support structure 216 but it also acts as a vibration absorption member to absorb any vibrational movement existing between heat exchanger 200 and adjacent support structure 216 .
- the normal circuit traversed by the fluid which flows through heat exchanger 200 is shown generally by the direction of the arrows set forth in FIG. 2 .
- fluid enters 218 CHAMBER A by way of upper header tank opening 220 .
- the fluid flows downward through a plurality of cooling tubes 204 ′ into the left hand portion of CHAMBER B.
- fluid flows from the left hand portion of CHAMBER B to the right hand portion of CHAMBER B and, thereafter, flows upward through cooling tubes 204 ′′ to CHAMBER C within upper header tank 206 .
- the fluid exits 222 by way of upper header tank opening 224 .
- stop baffle 226 is to prevent the direct passage of fluid from CHAMBER A to CHAMBER C.
- Other stop baffles 228 , 230 , 232 and 234 are present to confine the flow of fluid to one or more chambers within heat exchanger 200 .
- upper header tank 206 may be formed with one or more openings 236 , 238 , 240 , and 242 which are adapted to receive various components comprising heat exchanger 200 .
- openings 238 , 240 , and 242 are appropriately sized and positioned along a bottom surface of upper header tank 206 to accommodate respectively associated cooling tube 238 ′, 240 ′ and 242 ′.
- Opening 236 is sized and positioned to accept stop baffle 226 .
- Stop baffle 236 includes a bottom portion that generally conforms to the inner contour 246 of upper header tank 206 .
- the inner contour of upper header tank 206 is generally circular and accordingly, the bottom portion 244 of stop baffle 226 is generally circular.
- At least one of the sidewalls 248 , 250 of stop baffle 226 includes a portion which is adapted to register with a mating member 256 , 258 of upper header tank 206 .
- portions 252 , 254 include a notch and mating members 256 , 258 include a tab 256 , 258 which is sized and positioned to generally engage its respectively associated notch 252 , 254 .
- Mating member 256 , 258 may be formed in upper header tank 206 in the same operation wherein opening 236 is formed in upper header tank 206 . This process will be discussed more fully in conjunction with FIGS. 22A and 22B .
- baffle 226 One of the traditional problems associated with fabricating heat exchangers is that it is difficult to maintain all of the components in their respective locations between the assembly process and the furnace brazing process. By fashioning baffle 226 with portions 248 , 250 that mate with receiving members 256 , 258 of upper header tank 206 , baffle 226 will remain in its desired location until furnace brazing is complete.
- FIG. 4 shows the final assembly of all of the members shown in FIG. 3 after furnace brazing is complete.
- mating members 256 , 258 can be located such that they frictionally engage a side portion 252 , 254 of stop baffle 226 .
- mating members 256 , 258 By appropriately sizing and locating mating members 256 , 258 they can be made to frictionally engage one or more side portions 252 , 254 of stop baffle 226 such that stop baffle 226 can be easily inserted into opening 236 but thereafter the engagement between 256 , 258 and respectively associated side portions 252 , 254 offers some resistance against removal of baffle 226 from its registration with mating members 256 , 258 . In many applications, the removal resistance offered by the frictional engagement (i.e.
- baffle 226 and members 256 , 258 are sufficient to keep stop baffle 226 properly located within opening 236 until furnace brazing can take place. If a given application calls for greater retention than that offered by the interference fit between baffle 226 and members 256 , 258 , members 256 , 258 may be crimped inwardly (toward each other) thereby squeezing baffle 226 therebetween.
- FIG. 5D shows an embodiment where members 256 , 258 have been crimped (i.e. deformed) inwardly thereby causing baffle 260 to be squeezed between members 256 , 258 .
- mating members 256 , 258 are sized and positioned to operatively engage a respectively associated notch portion 252 , 254 of stop baffle 226 .
- stop baffle 226 By fashioning stop baffle 226 with one or more notch portions 252 , 254 an enhanced pull out resistance is made available to stop baffle 226 .
- baffle 226 has thus far been focused on a stop baffle, other baffle types can be employed depending on the configuration of the heat exchanger 200 at hand.
- a stop baffle 260 is provided wherein the stop baffle 260 includes a mounting hole 278 or “eye” formed in a portion of stop baffle which extends from an outer surface of header tank 206 , 208 (see FIG. 5B ).
- a stop baffle 262 is provided wherein the stop baffle includes a flanged eye portion 264 .
- the flanged eye 264 can be used in any number of configurations where mounting baffle 262 to an external component is desirable.
- An inner opening 266 of flanged eye portion 264 may be threaded to accept a threaded fastener.
- a stop baffle 268 may be fashioned having one or more grip fingers 270 , 272 to attach to (or wrap around) an adjacent member such as a tube 274 , structural member, or the like (see FIG. 5F ).
- Stop baffle may be fabricated having two or more openings in the portion of the baffle 262 extending from the outer portion of header tank 206 , 208 .
- the stop baffle 276 embodiment shown in FIG. 5G shows two openings 278 , 280 formed in a portion of stop tab 276 which extends from header tank 206 , 208 .
- One of these openings, 278 is a conventional mounting eye (similar to that shown in FIG. 5B ) and the other opening 280 , is a flanged eye similar to that shown in FIGS. 5D and 5E .
- FIGS. 5H and 5I show a stop baffle that includes a planar surface 284 that is intersected by two spaced planar surfaces 286 , 288 .
- the two spaced planar surfaces 286 , 288 can be generally parallel to one another although it is not necessary for them to be parallel and the surfaces can be blended together at one of their end portions by way of a curvilinear surface 290 .
- stop baffle 260 one application for the embodiment of stop baffle 260 (see FIG. 5B ) is in attaching a rubber isolator 212 to an end portion of header tanks 206 , 208 for the purpose of mounting the end portion of header tanks 206 , 208 to an adjacent support structure 216 .
- an opening 284 (mounting eye) is fashioned in stop baffle 260 such that a male receiving portion 286 of rubber isolator 212 resides within mounting eye 284 .
- rubber isolator 212 can be fashioned to surround 288 , 290 an outer periphery of header tank 206 , 208 .
- An additional point of contact between isolator 212 and header tank 206 , 208 can be established at a contact region 292 between rubber isolator 212 and stop baffle 260 .
- An end portion 290 of rubber isolator 212 is sized to be received within an opening 292 of adjacent support structure 216 .
- baffle type which blocks fluid flow
- baffle type which allows fluid to flow therethrough.
- FIG. 7 which, in all ways resembles the stop baffle of FIGS. 5B and 5C except that the baffle has an opening 298 which allows fluid to pass through the baffle.
- This type of baffle is known as a “pass through” baffle.
- I/O member header tank 206 , 208
- baffle 296 can be used to support I/O member 300 at a point 306 which is remote from the fluid tight point of connection 302 between I/O member 300 and header tank 206 , 208 . Pass through baffle 296 can be fitted with opening 278 which serves as a strain relief for I/O member 300 .
- FIG. 8 depicts the combinatorial use of baffles 226 , 296 inasmuch as a first baffle (stop baffle 226 ) is used on one side of connection 302 to prevent the flow of fluid from CHAMBER E to CHAMBER D, and a second baffle (pass through baffle 296 ) is used as a strain relief member for supporting I/O member 300 while still allowing fluid to pass from CHAMBER E to CHAMBER F.
- a first baffle stop baffle 226
- baffle pass through baffle 296
- any number of baffles can be used in combination to create any number of fluid flow circuits within a heat exchanger to accomplish any number of functions described herein that are associated with the use of baffles.
- both a stop baffle 226 and a pass through baffle 296 are used in a way such that they perform a strain relief function for I/O member 300 .
- I/O member 300 passes through an opening in header tank 206 , 208 thereby forming a junction between the two capable of transmitting fluid. This junction contains a high stress joint 302 which, if not adequately reinforced, may result in premature failure of the fluid connection between member 300 and header tank 206 , 208 .
- an upper portion 304 of stop baffle 226 abuts I/O member 300 along a first side of I/O member 300 and an upper portion 306 of pass through baffle 296 abuts a second side portion of I/O member 300 .
- the system of FIG. 10 includes saddle coupling 308 for relieving the strain formed at the joint 302 between I/O member 300 and header tank 206 , 208 .
- Saddle coupling 308 may be fabricated from any number of materials including stamped or cast metal and is fitted with an opening 310 to receive I/O member 300 .
- Saddle coupling 308 includes laterally spaced legs 312 , 314 which terminate into respectively associated crimp tabs 316 , 318 .
- Saddle coupling 308 also includes an integral stop baffle 320 which is sized and positioned to pass through opening 322 of header tank 206 , 208 .
- stop baffle 320 When saddle coupling 308 is assembled to header tank 206 , 208 , stop baffle 320 is receivingly engaged in opening 322 and crimp tabs 316 , 318 can be squeezed around header tank 206 , 208 such that they positively retain saddle coupling 308 to header tank 206 , 208 (see FIG. 11 ).
- I/O member 300 can be fashioned with an upset 324 so that the maximum penetration of I/O member 300 into the inner cavity 326 of header tank 206 , 208 is controlled. Stop baffle 320 performs the same function (i.e.
- baffle 320 is shown as a stop baffle, other baffle types (e.g. pass through baffles can also be incorporated into saddle coupling 308 ). After the assembly of FIG. 10 through FIG. 12 is joined (by furnace brazing or the like), a strong, fatigue resistant joint 302 is formed.
- stop baffle 226 can be used (in the manner already described herein) to form an end portion of header tank 206 , 208 .
- stop baffle 226 forms a fluid tight seal against the fluid contained within header tank 206 , 208 .
- Stop baffle 326 can be fashioned directly to an end portion of header tank 206 , 208 (as shown in FIG. 13 ) or, the end portion 326 of header tank 206 , 208 can be fitted with a standard radiator cap fitting 330 (see FIG. 14 ).
- structural side member 210 may be fastened to header tank 206 , 208 by inserting a tabbed portion 332 of structural side member 210 through a receiving opening of header tank 206 , 208 and thereafter furnace brazing (or otherwise joining) the two members together.
- FIG. 16 depicts displacing the tab portion 332 of structural side member 210 such that it forms a mushroom head to mechanically interlock with header tank 206 , 208 .
- This mechanical interlock is not a replacement for furnace brazing (or other means of joining) but it merely re-enforces the mechanical strength of the joint entire unit once the assembly fabrication is complete.
- FIG. 17 it is often desirable to join two heat exchangers in an adjacent configuration, such is common in automobiles wherein the engine radiator is placed in close proximity to the air conditioning condenser. If such a juxtaposition of two heat exchangers is desirable, the arrangement in FIG. 17 can be used wherein the header tank 106 of the first heat exchanger 336 is formed with a first portion 340 that is engagingly received by a mating portion 342 of a second header tank 106 ′. If tanks 106 , 106 ′ are formed by extrusion, portion 340 and mating portion 342 can be easily formed during the extrusion process 340 , 342 may be continuous (i.e. formed without interruption) or they may be formed at intervals along header tanks 106 , 106 ′.
- Portions 340 , 342 may appear on both upper and lower tanks. It may also be desirable to fashion a rubber hood seal 340 to header tank 106 to form a seal between header tank 106 and the underside of the vehicle hood (vehicle hood not shown). If this is the case, an engagement tab 342 can be fashioned on header tank 106 for receiving a mating portion 344 of hood seal 340 .
- FIGS. 18 and 19 An alternative embodiment for using portions 340 , 342 (formed into tanks 106 , 106 ′) for joining first heat exchanger 336 with second heat exchanger 338 is shown in FIGS. 18 and 19 .
- a connector 346 is used which includes first and second openings to engage the first and second header tanks 106 , 106 ′ of the respectively associated first and second heat exchangers 336 , 338 .
- connector 346 is shown as a single connector in FIGS. 18A, 18B , and 19 , it is envisioned that a similar connector may be used to interconnect the bottom header tanks of the heat exchangers 336 , 338 .
- Side supports 210 ′, 210 ′′ can be separate members (as shown in FIG.
- FIG. 18A or they can be a single member (as shown in FIG. 18B ).
- side supports 210 ′, 210 ′′ are fabricated from a single member, a stiffening bead 211 may be formed in the support 210 ′, 210 ′′ to impart rigidity.
- Connector 346 and supports 210 ′, 210 ′′ may be formed from steel stamping, plastic, or any other suitable materials. Stop baffles 226 , 226 ′ may be used to form end caps for the header of first and second heat exchangers 336 , 338 .
- a high pressure manifold 346 can be coupled to baffle 348 or it can be formed as an integral extension of baffle 348 .
- Baffle 348 can be any style of baffle that has been described herein.
- High pressure manifold 346 is effective for coupling high pressure fluid connections such as those found in air conditioning condensers.
- High pressure manifold 346 includes upper half 350 and lower half 352 . At least one of the halves 350 , 352 is coupled to (or integrally formed from) baffle 348 .
- Both of the halves 350 , 352 may be coupled to two or more baffles 348 or, in an alternative embodiment, one of the halves 350 , 352 may be connected to two or more baffles at two or more points along halves 350 , 352 .
- Baffle 348 is attached to an upper or lower header tank in the manner that has been discussed herein.
- Upper and lower half 350 , 352 may be fabricated from a metal stamping with or without a cladding as required for assembly brazing.
- High pressure manifold 346 may be used to replace high pressure manifolds currently being used which are fabricated using an expensive extruded materials.
- the high pressure manifold 346 can carry one set of tubes (such as inlet tubes 354 , 356 ) or two sets of tubes (such as inlet tubes 354 , 356 and outlet tubes 358 , 360 ).
- Tubes 354 , 360 may be joined to upper half 350 by way of furnace brazing or the like.
- Lower tubes 356 , 358 may be furnace brazed to lower half 352 .
- Inlet tube 356 may be formed with an upset portion 362 and outlet tube 358 may also be formed with an upset portion 364 .
- Upset portion 362 , 364 form part of a shoulder portion used to compress their respectively associated O-rings 366 , 368 when threaded fasteners 370 , 372 , and 374 are tightened.
- the high pressure manifold 346 forms an excellent high pressure seal for transferring high pressure fluids through inlet tubes 354 , 356 and outlet tubes 358 , 360 while avoiding the cost of expensive extruded materials.
- FIG. 21 shows an alternative embodiment to the high pressure manifold of FIG. 20 .
- upper half 350 is identical to lower half 352 . Accordingly, only one set of tooling is required to manufacture high pressure manifold 346 of FIG. 20 .
- Each tube 354 , 356 , 358 , 360 is connected to (by furnace brazing or the like) an extruded opening in either the upper half 350 or the lower half 352 of the assembly.
- Each half 350 , 352 includes a notch 376 , 378 for receiving an O-ring 366 , 368 .
- a center fastener 372 may or may not be required.
- header 206 , 208 may be formed using the following processes.
- Header 206 , 208 can be fabricated from any tubular material (such as extruded or welded tube). Header 206 , 208 can have a smooth wall (as shown in FIG. 22A ) or can be fabricated having fins or ribs running longitudinally along the header (see 340 , 342 in FIG. 17 ).
- One technique for forming either tube slots or baffle slots (hereinafter generically “slots”) in header 206 , 208 is to use hydropiercing technology.
- hydropiercing technology includes pressurizing header 206 , 208 with a pressured fluid and then concurrently acting on it with one or more tools 380 to form tube slots, baffle slots, or any other type of opening through the side wall of header 206 , 208 .
- tool 380 is pushed against header 206 , 208 until it pierces the side wall of header 206 , 208 and achieves the position generally shown in FIG. 22B .
- the chisel point 388 slightly coins the inside (i.e. bottom) surface of 206 , 208 .
- Tool 380 may have a rectangular cross section throughout its body portion 382 and terminate into a piercing portion 384 .
- the piercing portion 384 when viewed from a front elevational view may have a radius 386 which generally matches the inner radial diameter R of header 206 , 208 .
- tool 380 When viewed from a side profile (see FIG. 23C ), tool 380 terminates into a chisel point 388 which may begin 391 in a region between an origin 383 of radius 386 and an end point 392 of tool 380 .
- the angle ⁇ of the chisel point may be 20° as measured from a vertical edge of tool 380 .
- mating members (or tabs) 256 By offsetting the beginning of chisel point 390 lower than the origin 383 of radius 386 , mating members (or tabs) 256 (see FIG. 22B ) are formed as tool 380 penetrates the side wall of header 206 , 208 .
- the function of mating member (or tabs) 256 has been thoroughly discussed in the prior portions of this disclosure.
- FIG. 23A is a front elevational view of a tool that has a generally rectangular body 396 and has a piercing portion 398 that when viewed from the front elevational view includes side portions having a concave profile 400 , 402 .
- a tool 404 is formed having a generally rectangular body portion 406 and a piercing portion 408 that when viewed from a front elevational view has tapering sides 410 , 412 that taper generally linearly.
- piercing operations which are carried out using a pressurized fluid to pressurize the inner chamber of a work piece are known as hydropierce operations.
- the method of forming tabs 256 as disclosed herein can be accomplished using either hydropiercing or air dye operations.
- the bell mouth distortion 414 typically left behind after a hydropierce operation or an air dye operation, can provide a good mating surface for braze soldering a tube within the bell mouth opening 416 or, the opening 416 may be threaded for accepting a threaded fastener (see FIG. 28 ).
- Tool base 418 supports multiple piercing tools 420 .
- Tool base is attached to platen 422 .
- Platen 422 is capable of reciprocating upwardly and downwardly 428 by way of reciprocating drive 430 .
- One or more stripper springs 426 connect stripper rail 424 to tool base 418 .
- Stripper rail 424 has a plurality of openings (exemplified at 427 in FIG.
- Base 432 supports reservoir 434 which contains a non-compressible fluid (such as water, oil or the like). Reservoir 434 supports cradle 436 which is generally formed to conformingly support a portion of an outer surface of work piece 438 . Cradle 436 is flanked by one or more plunger assemblies 440 , 442 . The function of plunger assemblies 440 , 442 will be explained more fully in conjunction with FIG. 36 through FIG. 39 .
- Each plunger assembly 440 , 442 may be furnished with a pressure relief valve 444 , 446 for relieving an overpressure condition that might develop.
- the function of pressure relief valve 444 , 446 will be discussed in greater detail in conjunction with FIG. 36 through FIG. 39 .
- a bottom portion 447 of stripper rail 424 is formed 448 to conform to an outside surface of work piece 438 .
- upper surface 449 of cradle 436 includes a portion 450 which is generally formed to conform to an outer surface of work piece 438 .
- Contour 448 and 450 ensure that work piece 438 does not move once the multiple pierce tools 420 begin their piercing operation.
- FIGS. 34, 35 and 36 at the point where piercing portion 384 of tool 380 begins to carry out its piercing operation, the position of the operative components are generally shown in FIGS. 34 and 35 .
- Drive arms 456 , 458 are carried by platen 422 .
- the function of drive arms 456 , 458 is to activate a respectively associated plunger assembly 440 , 442 to hydraulically pressurize an inner chamber 426 of work piece 438 . Because the operation of each plunger assembly 440 , 442 is identical, only plunger assembly 440 will be discussed hereinafter. Everything that is described herein relating to plunger assembly 440 and its associated drive arm 456 directly applies to plunger assembly 442 and its respective drive arm 458 .
- Plunger assembly 440 may include, in an embodiment, slide block 460 , plunger 462 , plunger return spring 464 , and guide block 466 (see FIG. 36 ).
- Drive arm 456 includes canted work surface 457 and sliding block 460 includes canted work surface 459 (see FIG. 32 ).
- Sliding block 460 is adapted to slide in a horizontal motion.
- any further downward motion of drive arm 456 causes slide block 460 to move in a horizontal 468 direction.
- plunger 462 moves into engagement with the end opening 470 of work piece 438 .
- pressure relief valve 444 is provided in hydraulic communication 466 with the fluid pressure within inner chamber 438 .
- pressure relief valve 444 is the type of pressure relief valve which is field adjustable so that the optimum internal pressure can be set once all operating conditions and tolerances are in play.
- FIGS. 37, 38 and 39 when platen 422 is at the lower most portion of its downstroke, the configuration of the component parts are generally as depicted in FIGS. 37, 38 and 39 .
- FIG. 38 depicts tool 380 at the lower most portion of its downstroke wherein tabs 256 are formed in the side walls of work piece 438 in an identical manner to that which has already been described in conjunction with FIGS. 22A, 21 and 22 B.
- sliding block 460 is at the left most extreme portion of its stroke (as depicted in FIG. 39 , this means that block 460 has traveled to its maximum, left most extent).
- plunger 462 is shown at its left most travel extent.
- Plunger 462 may include fluid communication channel 472 and guide block 466 may include fluid communication channel 474 . If at least one of the fluid communication channels 472 , 474 includes a channel slot 476 which is generally oriented parallel to the movement 468 of plunger 462 , pressure relieve valve 444 can monitor the pressure developed within inner chamber 246 of work piece 438 irrespective of where plunger 462 is in its stroke.
- guide block 466 is fashioned with channel slot 476 . Channel 476 is generally parallel to the direction 468 of the plunger stroke.
- channel slot 476 can just as easily be formed in plunger 462 and still accomplish the function of allowing pressure relief valve 444 to be uninterrupted fluid communication with the pressure developed within inner chamber 246 of work piece 238 during the piercing operation.
- one or more lower pierce tools 478 can be added to the pierce tool apparatus to compliment the upper pierce tools 380 that have already been discussed.
- Lower pierce tools 478 are mechanically, hydraulically, electrically or the like connected 482 to a pierce tool driver mechanism 480 .
- Pierce tool driver mechanism 480 is synchronized to the controls which otherwise operate the entire pierce tool apparatus in a way that allows the pierce tool driver 480 to raise one or more lower pierce tools 478 at the appropriate time so that bottom slots can be placed in workpiece 238 simultaneously, or generally simultaneously, with the placement of upper slots in workpiece 238 by one or more upper pierce tools 380 .
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- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
A baffle having a body portion that includes at least one side wall. The side wall geometry is adapted to register with a mating surface of a tube. A heat exchanger assembly including a baffle, and a tool for forming a slot in a heat exchanger for accepting a baffle is also disclosed.
Description
- This application claims priority to U.S. provisional patent application Ser. No. 60/632,641 filed on Dec. 2, 2004.
- This application generally relates to heat exchangers and more particularly relates to heat exchangers that incorporate internal baffles for directing fluid flow in the heat exchanger.
- Now referring to
FIG. 1 ,typical heat exchangers 100 include acore assembly 102 positioned between an upper 106 and lower 108 header tank.Core assembly 102 is traditionally comprised of alternating layers ofcooling tubes 104 andfins 105. It is typical forfins 105 to be formed in a serpentine shape and to be fastened, at numerous contact points, to two adjacent cooling tubes. Eachcooling tube 104 extends betweenspaced header tanks header tanks tubes 104 extend to theheader tanks - Under normal operation, a first fluid flows from one
header tank other header tank cooling tube 104. A second fluid, typically ambient air, passes over an outside surface of thecooling tubes 104 and thefins 106. If the second fluid has a lower temperature than the first fluid, the fluid in theheat exchanger 100 will be cooled as it flows betweenheader tanks - In many applications, it is desirable to divide one or more of the
header tanks header tanks heat exchangers 100. The present invention also sets forth numerous structures for attaching ancillary hardware to heat exchangers. - Further features and advantages of the invention will become apparent from consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
-
FIG. 1 is a prior art heat exchanger; -
FIG. 2 is a partial cross sectional view of an embodiment of a heat exchanger of the present invention; -
FIG. 3 is a partial exploded view of the header tank and supporting components found withinencircled portion 3 ofFIG. 2 ; -
FIG. 4 is an assembled view of the components ofFIG. 3 ; -
FIG. 5A-5J are various embodiments of a baffle and baffle/tube assemblies of the present invention; -
FIG. 6 is a partial cross sectional view of an end portion of a header tank employing a baffle and a rubber isolator to mount a heat exchanger to an adjacent support structure; -
FIG. 7 is a partial cross sectional view of a pass through baffle joined to a header tank; -
FIG. 8 is a partial cross sectional view of a header tank employing a stop baffle and a pass through baffle wherein the pass through baffle engages an inlet/outlet tubular member to provide strain relief to the inlet/outlet tubular member; -
FIG. 9 is a partial cross sectional view of a stop baffle and a pass through baffle wherein both the stop baffle and the pass through baffle perform a strain relief function for an inlet/outlet member; -
FIG. 10 is a partial exploded view of a header tank, a saddle coupling, and an I/O member wherein the saddle coupling employs an integrated baffle; -
FIG. 11 is a partial cross sectional view taken substantially through lines 11-11 ofFIG. 10 ; -
FIG. 12 is a partial cross sectional view taken substantially along lines 12-12 ofFIG. 10 ; -
FIG. 13 is a partial cross sectional view showing a header tank employing a stop baffle as a terminal end cap for the header tank; -
FIG. 14 is a partial cross sectional view showing a header tank employing a standard radiator cap connector at a terminal end of the header tank; -
FIG. 15 is a partial cross sectional view showing a joint between a header tank and a tabbed portion of a structural side member; -
FIG. 16 is a partial cross sectional view showing a method of attaching a structural side member to a header tank by displacing material from the structural side member; -
FIG. 17 is a partial cross sectional view of first and second heat exchangers wherein the header tanks of the respectively associated first and second heat exchangers are joined using mating members; -
FIG. 18A is a side elevational view of a first and second heat exchanger assembly employing a connector plate to join the first and second heat exchangers along an end portion of their respectively associated header tanks. -
FIG. 18B is a side elevational view of a first and second heat exchanger assembly employing a common side support member. -
FIG. 19 is a partial cross sectional view taken substantially along lines 19-19 ofFIG. 18 . -
FIG. 20 is a partial cross sectional view of an embodiment of a high pressure manifold connected to a baffle. -
FIG. 21 is a partial cross sectional view of yet another embodiment of a high pressure manifold connected to a baffle. -
FIG. 22A is a depiction of a pierce tool aligned with a work piece to be operated on by the pierce tool. -
FIG. 22B is a depiction of a pierce tool after it has worked upon a work piece. -
FIG. 22C is a side elevational view of the pierce tool ofFIG. 22A . -
FIG. 23A is a front elevational view of a tool having a piercing portion that includes a concave side profile. -
FIG. 23B is a side elevational view of the tool ofFIG. 23A . -
FIG. 24A is a front elevational view of a tool having a profile with generally linearly tapered sides. -
FIG. 24B is a side elevational view of a tool ofFIG. 24A . -
FIG. 25 is a side elevational view of a pierce tool which has pierced through a work piece while the work piece has an inner chamber which is exposed to pressurized fluid. -
FIG. 26 is a pierce tool which has pierced through a work piece while an inner chamber of the work piece is exposed to atmospheric pressure. -
FIG. 27 is a partial cross sectional view of a bell mouth opening created in a side wall of a work piece. -
FIG. 28 is a partial cross sectional view of a bell mouth opening which has been formed by a pierce operation through the side wall of a work piece wherein the bell mouth opening has been threaded to accept a threaded fastener. -
FIG. 29 is an assembly showing multiple pierce tools affixed to a tool base. -
FIG. 30 is a front elevational view of a piercing apparatus used to pierce multiple slots in a work piece. -
FIG. 31 is a partial cross sectional view taken substantially through lines 31-31 ofFIG. 30 . -
FIG. 32 is the apparatus ofFIG. 30 shown in an intermediate, descending position. -
FIG. 33 is a partial cross sectional view taken substantially through lines 33-33 ofFIG. 32 . -
FIG. 34 is the apparatus ofFIG. 30 shown in a position just prior to pierce tools piercing a work piece. -
FIG. 35 is a partial cross sectional view taken substantially through lines 35-35 ofFIG. 34 . -
FIG. 36 is an enlarged view of a plunger assembly and associated components shown substantially within encircledportion 36 ofFIG. 34 . -
FIG. 37 is the apparatus ofFIG. 30 wherein pierce tools are positioned in the lower most portion of their downward stroke. -
FIG. 38 is a partial cross sectional view taken substantially through lines 38-38 ofFIG. 37 . -
FIG. 39 is an enlarged view of the plunger assembly and related components found within encircled portion 39 ofFIG. 37 . -
FIG. 40 is a partial cross sectional view of another embodiment of a piercing apparatus having both upper piercing tools and lower piercing tools. - Now referring to
FIG. 2 ,heat exchanger 200 includesupper header tank 206,lower header tank 208 and a plurality ofcooling tubes 204 that communicate a fluid betweenupper header tank 206 andlower header tank 208. Astructural side member 210 can, optionally, be used to bindupper header tank 206 tolower header tank 208 thereby giving the entire assembly greater mechanical strength than that which may be present if coolingtubes 204 were the sole means of tyingupper header tank 206 tolower header tank 208. Optionalstructural side member 210 can be fastened toupper header tank 206 and lower header tank in any number of ways known to those skilled in the art. For example,member 210 can be brazed to an outer surface of theheader tanks FIG. 2 , it can be received within an opening in a sidewall portion ofheader tanks - A rubber isolator or the like 212, 214 may be used to structurally mount
heat exchanger 200 to anadjacent support structure 216.Rubber isolator heat exchanger 200 toadjacent support structure 216 but it also acts as a vibration absorption member to absorb any vibrational movement existing betweenheat exchanger 200 andadjacent support structure 216. - In the heat exchanger embodiment shown in
FIG. 2 , the normal circuit traversed by the fluid which flows throughheat exchanger 200 is shown generally by the direction of the arrows set forth inFIG. 2 . Specifically, fluid enters 218 CHAMBER A by way of upperheader tank opening 220. From CHAMBER A, the fluid flows downward through a plurality ofcooling tubes 204′ into the left hand portion of CHAMBER B. Next, fluid flows from the left hand portion of CHAMBER B to the right hand portion of CHAMBER B and, thereafter, flows upward throughcooling tubes 204″ to CHAMBER C withinupper header tank 206. From CHAMBER C, the fluid exits 222 by way of upperheader tank opening 224. In the above-referenced embodiment, it is desirable to eliminate fluid flow directly between CHAMBER A and CHAMBER C. If fluid were allowed to “leak” directly between CHAMBER A and CHAMBER C (without having to traverse through CHAMBER B) the cooling effect offered by coolingtubes 204 would be greatly reduced. One of the functions ofstop baffle 226 is to prevent the direct passage of fluid from CHAMBER A to CHAMBER C. Other stop baffles 228, 230, 232 and 234 are present to confine the flow of fluid to one or more chambers withinheat exchanger 200. - Now referring to
FIGS. 2 and 3 ,upper header tank 206 may be formed with one ormore openings heat exchanger 200. Specifically,openings upper header tank 206 to accommodate respectively associatedcooling tube 238′, 240′ and 242′.Opening 236 is sized and positioned to acceptstop baffle 226. - Stop
baffle 236 includes a bottom portion that generally conforms to theinner contour 246 ofupper header tank 206. In the example set out inFIG. 3 , the inner contour ofupper header tank 206 is generally circular and accordingly, thebottom portion 244 ofstop baffle 226 is generally circular. At least one of thesidewalls stop baffle 226 includes a portion which is adapted to register with amating member upper header tank 206. In the embodiment shown in FIG. 3,portions mating members tab notch Mating member upper header tank 206 in the same operation whereinopening 236 is formed inupper header tank 206. This process will be discussed more fully in conjunction withFIGS. 22A and 22B . - One of the traditional problems associated with fabricating heat exchangers is that it is difficult to maintain all of the components in their respective locations between the assembly process and the furnace brazing process. By fashioning
baffle 226 withportions members upper header tank 206, baffle 226 will remain in its desired location until furnace brazing is complete.FIG. 4 shows the final assembly of all of the members shown inFIG. 3 after furnace brazing is complete. - Now referring to
FIGS. 4 and 5 A,mating members side portion stop baffle 226. By appropriately sizing and locatingmating members more side portions stop baffle 226 such thatstop baffle 226 can be easily inserted intoopening 236 but thereafter the engagement between 256, 258 and respectively associatedside portions baffle 226 from its registration withmating members baffle 226 andmembers stop baffle 226 properly located within opening 236 until furnace brazing can take place. If a given application calls for greater retention than that offered by the interference fit betweenbaffle 226 andmembers members baffle 226 therebetween.FIG. 5D shows an embodiment wheremembers baffle 260 to be squeezed betweenmembers mating members notch portion stop baffle 226. By fashioningstop baffle 226 with one ormore notch portions baffle 226. - Although the discussion of
baffle 226 has thus far been focused on a stop baffle, other baffle types can be employed depending on the configuration of theheat exchanger 200 at hand. For example, in some heat exchangers, astop baffle 260 is provided wherein thestop baffle 260 includes a mountinghole 278 or “eye” formed in a portion of stop baffle which extends from an outer surface ofheader tank 206, 208 (seeFIG. 5B ). - In another baffle embodiment (see
FIG. 5D ), astop baffle 262 is provided wherein the stop baffle includes aflanged eye portion 264. Theflanged eye 264 can be used in any number of configurations where mountingbaffle 262 to an external component is desirable. Aninner opening 266 offlanged eye portion 264 may be threaded to accept a threaded fastener. - In still yet another embodiment of a stop baffle, a
stop baffle 268 may be fashioned having one ormore grip fingers tube 274, structural member, or the like (seeFIG. 5F ). Stop baffle may be fabricated having two or more openings in the portion of thebaffle 262 extending from the outer portion ofheader tank stop baffle 276 embodiment shown inFIG. 5G shows twoopenings stop tab 276 which extends fromheader tank FIG. 5B ) and theother opening 280, is a flanged eye similar to that shown inFIGS. 5D and 5E . -
FIGS. 5H and 5I show a stop baffle that includes aplanar surface 284 that is intersected by two spacedplanar surfaces planar surfaces curvilinear surface 290. - Now referring to
FIG. 6 , one application for the embodiment of stop baffle 260 (seeFIG. 5B ) is in attaching arubber isolator 212 to an end portion ofheader tanks header tanks adjacent support structure 216. As shown inFIG. 6 , an opening 284 (mounting eye) is fashioned instop baffle 260 such that amale receiving portion 286 ofrubber isolator 212 resides within mountingeye 284. Additionally,rubber isolator 212 can be fashioned to surround 288, 290 an outer periphery ofheader tank isolator 212 andheader tank contact region 292 betweenrubber isolator 212 and stopbaffle 260. Anend portion 290 ofrubber isolator 212 is sized to be received within anopening 292 ofadjacent support structure 216. By engagingmember 286 within mountingeye 284 and, in addition, establishing points ofcontact isolator 212 securely engages theassembly support structure 216 while still being vibrationally isolated therefrom. - Although the function of the baffle as it has been discussed so far has focused on a baffle type which blocks fluid flow, (i.e. stop baffle 226), there are some applications where it is desirable to have a baffle type that allows fluid to flow therethrough. Such a baffle type is shown in
FIG. 7 which, in all ways resembles the stop baffle ofFIGS. 5B and 5C except that the baffle has anopening 298 which allows fluid to pass through the baffle. This type of baffle is known as a “pass through” baffle. One application of the pass through baffle will now be explained in conjunction withFIGS. 7 and 8 . Often times it is desirable to connect an inlet or outlettubular member 300 withheader tank 206, 208 (hereinafter I/O member). Although such a connection is relatively easy to achieve, the vibrational forces experienced under normal vehicle operation by the components of theheat exchanger 304 cause high stresses at the fixation points 302 (i.e. point of joining) between I/O member 300 andheader tank baffle 296 can be used to support I/O member 300 at apoint 306 which is remote from the fluid tight point ofconnection 302 between I/O member 300 andheader tank baffle 296 can be fitted withopening 278 which serves as a strain relief for I/O member 300. Once the assembly shown inFIG. 7 is joined with I/O member 300 and the entire assembly is furnace brazed (or otherwise joined together) it provides an excellent rigid structure which eliminates joint failure atconnection 302.FIG. 8 depicts the combinatorial use ofbaffles connection 302 to prevent the flow of fluid from CHAMBER E to CHAMBER D, and a second baffle (pass through baffle 296) is used as a strain relief member for supporting I/O member 300 while still allowing fluid to pass from CHAMBER E to CHAMBER F. As will be understood by those skilled in the art, any number of baffles can be used in combination to create any number of fluid flow circuits within a heat exchanger to accomplish any number of functions described herein that are associated with the use of baffles. - In the embodiment of
FIG. 9 , both astop baffle 226 and a pass throughbaffle 296 are used in a way such that they perform a strain relief function for I/O member 300. In the embodiment shown inFIG. 9 , I/O member 300 passes through an opening inheader tank member 300 andheader tank upper portion 304 ofstop baffle 226 abuts I/O member 300 along a first side of I/O member 300 and anupper portion 306 of pass throughbaffle 296 abuts a second side portion of I/O member 300. Once the assembly as shown inFIG. 9 is furnace brazed, or the like,upper portions 304, 306 (at their points of contact with 300), form strong joints that reduces the strain on joint 302. This provides an assembly having excellent resistance against fatigue fracturing alongjoint 302. - Now referring to
FIG. 10 , if an even greater strain relief capacity is necessary than that of the arrangement shown inFIG. 9 , the system ofFIG. 10 can be used. The system ofFIG. 10 includessaddle coupling 308 for relieving the strain formed at the joint 302 between I/O member 300 andheader tank Saddle coupling 308 may be fabricated from any number of materials including stamped or cast metal and is fitted with anopening 310 to receive I/O member 300.Saddle coupling 308 includes laterally spacedlegs crimp tabs Saddle coupling 308 also includes anintegral stop baffle 320 which is sized and positioned to pass through opening 322 ofheader tank saddle coupling 308 is assembled toheader tank baffle 320 is receivingly engaged inopening 322 and crimptabs header tank saddle coupling 308 toheader tank 206, 208 (seeFIG. 11 ). I/O member 300 can be fashioned with an upset 324 so that the maximum penetration of I/O member 300 into theinner cavity 326 ofheader tank baffle 320 performs the same function (i.e. prevents the passage of fluid) as the other stop baffles as discussed herein. Althoughbaffle 320 is shown as a stop baffle, other baffle types (e.g. pass through baffles can also be incorporated into saddle coupling 308). After the assembly ofFIG. 10 throughFIG. 12 is joined (by furnace brazing or the like), a strong, fatigue resistant joint 302 is formed. - Now referring to
FIG. 13 , theend portion 326 ofheader tanks baffle 226 can be used (in the manner already described herein) to form an end portion ofheader tank stop baffle 226 forms a fluid tight seal against the fluid contained withinheader tank baffle 326 can be fashioned directly to an end portion ofheader tank 206, 208 (as shown inFIG. 13 ) or, theend portion 326 ofheader tank FIG. 14 ). - As shown in
FIGS. 15 and 16 ,structural side member 210 may be fastened toheader tank portion 332 ofstructural side member 210 through a receiving opening ofheader tank FIG. 16 depicts displacing thetab portion 332 ofstructural side member 210 such that it forms a mushroom head to mechanically interlock withheader tank - It is often desirable to join two heat exchangers in an adjacent configuration, such is common in automobiles wherein the engine radiator is placed in close proximity to the air conditioning condenser. If such a juxtaposition of two heat exchangers is desirable, the arrangement in
FIG. 17 can be used wherein theheader tank 106 of thefirst heat exchanger 336 is formed with afirst portion 340 that is engagingly received by amating portion 342 of asecond header tank 106′. Iftanks portion 340 andmating portion 342 can be easily formed during theextrusion process header tanks mating portions first heat exchanger 336 withsecond heat exchanger 338 is eliminated.Portions rubber hood seal 340 toheader tank 106 to form a seal betweenheader tank 106 and the underside of the vehicle hood (vehicle hood not shown). If this is the case, anengagement tab 342 can be fashioned onheader tank 106 for receiving amating portion 344 ofhood seal 340. - An alternative embodiment for using
portions 340, 342 (formed intotanks first heat exchanger 336 withsecond heat exchanger 338 is shown inFIGS. 18 and 19 . In this embodiment, aconnector 346 is used which includes first and second openings to engage the first andsecond header tanks second heat exchangers connector 346 is shown as a single connector inFIGS. 18A, 18B , and 19, it is envisioned that a similar connector may be used to interconnect the bottom header tanks of theheat exchangers FIG. 18A ) or they can be a single member (as shown inFIG. 18B ). If side supports 210′, 210″ are fabricated from a single member, a stiffeningbead 211 may be formed in thesupport 210′, 210″ to impart rigidity. Also, by constructing side supports 210′, 210″ from a single member, the need forconnector 346 may be eliminated.Connector 346 and supports 210′, 210″ may be formed from steel stamping, plastic, or any other suitable materials. Stop baffles 226, 226′ may be used to form end caps for the header of first andsecond heat exchangers - Now referring to
FIG. 20 , ahigh pressure manifold 346 can be coupled to baffle 348 or it can be formed as an integral extension ofbaffle 348.Baffle 348 can be any style of baffle that has been described herein.High pressure manifold 346 is effective for coupling high pressure fluid connections such as those found in air conditioning condensers.High pressure manifold 346 includesupper half 350 andlower half 352. At least one of thehalves baffle 348. Both of thehalves more baffles 348 or, in an alternative embodiment, one of thehalves halves Baffle 348 is attached to an upper or lower header tank in the manner that has been discussed herein. Upper andlower half High pressure manifold 346 may be used to replace high pressure manifolds currently being used which are fabricated using an expensive extruded materials. Thehigh pressure manifold 346 can carry one set of tubes (such asinlet tubes 354, 356) or two sets of tubes (such asinlet tubes outlet tubes 358, 360).Tubes upper half 350 by way of furnace brazing or the like.Lower tubes lower half 352.Inlet tube 356 may be formed with anupset portion 362 andoutlet tube 358 may also be formed with anupset portion 364.Upset portion rings fasteners high pressure manifold 346 forms an excellent high pressure seal for transferring high pressure fluids throughinlet tubes outlet tubes -
FIG. 21 shows an alternative embodiment to the high pressure manifold ofFIG. 20 . In the embodiment ofFIG. 21 ,upper half 350 is identical tolower half 352. Accordingly, only one set of tooling is required to manufacturehigh pressure manifold 346 ofFIG. 20 . Eachtube upper half 350 or thelower half 352 of the assembly. Eachhalf notch ring members manifold 346, acenter fastener 372 may or may not be required. - Now referring to
FIGS. 22A and 22B ,header Header Header FIG. 22A ) or can be fabricated having fins or ribs running longitudinally along the header (see 340, 342 inFIG. 17 ). One technique for forming either tube slots or baffle slots (hereinafter generically “slots”) inheader header more tools 380 to form tube slots, baffle slots, or any other type of opening through the side wall ofheader header tool 380 is pushed againstheader header FIG. 22B . Preferably, whentool 380 is in its lower-most position (seeFIG. 22B ), thechisel point 388 slightly coins the inside (i.e. bottom) surface of 206, 208.Tool 380 may have a rectangular cross section throughout itsbody portion 382 and terminate into a piercingportion 384. The piercingportion 384 when viewed from a front elevational view may have aradius 386 which generally matches the inner radial diameter R ofheader FIG. 23C ),tool 380 terminates into achisel point 388 which may begin 391 in a region between anorigin 383 ofradius 386 and anend point 392 oftool 380. The angle θ of the chisel point may be 20° as measured from a vertical edge oftool 380. By offsetting the beginning ofchisel point 390 lower than theorigin 383 ofradius 386, mating members (or tabs) 256 (seeFIG. 22B ) are formed astool 380 penetrates the side wall ofheader - Although matching the radius R of
tool 380 to the inner diameter R ofheader tabs header FIG. 23A is a front elevational view of a tool that has a generallyrectangular body 396 and has a piercing portion 398 that when viewed from the front elevational view includes side portions having aconcave profile 400, 402. In another embodiment (seeFIGS. 24A and 24B ), atool 404 is formed having a generallyrectangular body portion 406 and a piercingportion 408 that when viewed from a front elevational view has taperingsides - If pressurized fluid is used during the piercing operation, the side walls of
header tool 380 do not distort inwardly to the extent that they would if pressurized fluid was not present within the inner cavity of theheader tube FIG. 25 (showing the distortion which is generally characteristic of a hydropierce operation) to the depiction ofFIG. 25 (which shows the distortion typically associated with a piercing operation where no pressurized fluid is used). When pierce operations are carried out without the use of pressurized fluid within the tubular member, it is commonly referred to as an “air dye” operation. In contrast, piercing operations which are carried out using a pressurized fluid to pressurize the inner chamber of a work piece are known as hydropierce operations. The method of formingtabs 256 as disclosed herein can be accomplished using either hydropiercing or air dye operations. The bell mouth distortion 414 (seeFIG. 27 ) typically left behind after a hydropierce operation or an air dye operation, can provide a good mating surface for braze soldering a tube within the bell mouth opening 416 or, theopening 416 may be threaded for accepting a threaded fastener (seeFIG. 28 ). - Although using a
single tool 380 may be used to create tube slots one-by-one or baffle slots one-by-one, it is envisioned that in a production environment, much faster processing times must be achieved. Accordingly, the methods and apparatus of the present invention are effective for mass producing heat exchanger headers by using the processes discussed below. - Individual piercing
tools 380 are assembled into a group of piercingtools 420. Multiple piercingtools 420 are all rigidly retained withintool base 418. Now referring toFIGS. 30 and 31 ,tool base 418 supports multiple piercingtools 420. Tool base is attached toplaten 422.Platen 422 is capable of reciprocating upwardly and downwardly 428 by way of reciprocatingdrive 430. One or more stripper springs 426connect stripper rail 424 totool base 418.Stripper rail 424 has a plurality of openings (exemplified at 427 inFIG. 30 ) that pass throughstripper rail 424 wherein eachopening 427 cooperates with a respectively associated piercedtool 380 in the plurality ofpierce tools 420.Base 432 supportsreservoir 434 which contains a non-compressible fluid (such as water, oil or the like).Reservoir 434 supportscradle 436 which is generally formed to conformingly support a portion of an outer surface ofwork piece 438.Cradle 436 is flanked by one ormore plunger assemblies plunger assemblies FIG. 36 throughFIG. 39 . Although only oneplunger assembly second plunger assembly 442 in some applications. Because bothplunger assemblies plunger assembly pressure relief valve pressure relief valve FIG. 36 throughFIG. 39 . Abottom portion 447 ofstripper rail 424 is formed 448 to conform to an outside surface ofwork piece 438. Likewise,upper surface 449 ofcradle 436 includes aportion 450 which is generally formed to conform to an outer surface ofwork piece 438.Contour work piece 438 does not move once themultiple pierce tools 420 begin their piercing operation. - Now referring to
FIGS. 32 and 33 , oncework piece 438 has been deposited into lower contour ofcradle 436, reciprocatingdrive 430 is activated thereby loweringplaten 422 which in turn lowers the entirepierce tool assembly 454.Stripper rail 424 is the first component ofpierce tool assembly 454 to contactcradle 436. Thereafter, aspierce tool assembly 454 continues its downward ascent,stripper spring 426 begins to compress thereby allowing the platen to continue its downward descent which drives eachpierce tool 380 towardwork piece 438. - Now referring to
FIGS. 34, 35 and 36, at the point where piercingportion 384 oftool 380 begins to carry out its piercing operation, the position of the operative components are generally shown inFIGS. 34 and 35 . Drivearms platen 422. The function ofdrive arms plunger assembly inner chamber 426 ofwork piece 438. Because the operation of eachplunger assembly only plunger assembly 440 will be discussed hereinafter. Everything that is described herein relating toplunger assembly 440 and its associateddrive arm 456 directly applies toplunger assembly 442 and itsrespective drive arm 458. -
Plunger assembly 440 may include, in an embodiment,slide block 460,plunger 462,plunger return spring 464, and guide block 466 (seeFIG. 36 ).Drive arm 456 includes cantedwork surface 457 and slidingblock 460 includes canted work surface 459 (seeFIG. 32 ). Slidingblock 460 is adapted to slide in a horizontal motion. Thus, whendrive arm 456 moves downwardly such thatcanted work surfaces drive arm 456 causes slideblock 460 to move in a horizontal 468 direction. Whenslide block 460 moves in a horizontal direction,plunger 462 moves into engagement with the end opening 470 ofwork piece 438. Whenplunger 462 contacts anopening 470 ofwork piece 438, it traps hydraulic fluid withininner chamber 438 of work piece. Thereafter, any further horizontal movement ofplunger 462 will pressurize the fluid withininner chamber 246 ofwork piece 438. This pressurized fluid minimizes the collapse of the sidewalls ofwork piece 438 during the hydropiercing operation (as has already been discussed in conjunction withFIGS. 25 and 26 ). In order to limit the magnitude of the hydraulic pressure developed withininner chamber 426 ofwork piece 438,pressure relief valve 444 is provided inhydraulic communication 466 with the fluid pressure withininner chamber 438. Preferably,pressure relief valve 444 is the type of pressure relief valve which is field adjustable so that the optimum internal pressure can be set once all operating conditions and tolerances are in play. - Now referring to
FIGS. 37, 38 and 39, when platen 422 is at the lower most portion of its downstroke, the configuration of the component parts are generally as depicted inFIGS. 37, 38 and 39.FIG. 38 depictstool 380 at the lower most portion of its downstroke whereintabs 256 are formed in the side walls ofwork piece 438 in an identical manner to that which has already been described in conjunction withFIGS. 22A, 21 and 22B. Also, when platen 422 is at the lower most portion of its downstroke, slidingblock 460 is at the left most extreme portion of its stroke (as depicted inFIG. 39 , this means thatblock 460 has traveled to its maximum, left most extent). In turn,plunger 462 is shown at its left most travel extent. -
Plunger 462 may includefluid communication channel 472 and guide block 466 may includefluid communication channel 474. If at least one of thefluid communication channels channel slot 476 which is generally oriented parallel to themovement 468 ofplunger 462, pressure relievevalve 444 can monitor the pressure developed withininner chamber 246 ofwork piece 438 irrespective of whereplunger 462 is in its stroke. In the embodiment shown inFIG. 39 ,guide block 466 is fashioned withchannel slot 476.Channel 476 is generally parallel to thedirection 468 of the plunger stroke. One skilled in the art will readily recognize thatchannel slot 476 can just as easily be formed inplunger 462 and still accomplish the function of allowingpressure relief valve 444 to be uninterrupted fluid communication with the pressure developed withininner chamber 246 ofwork piece 238 during the piercing operation. - Now referring to
FIG. 40 , in another embodiment of the piercing apparatus of the present invention, one or more lower piercetools 478 can be added to the pierce tool apparatus to compliment theupper pierce tools 380 that have already been discussed.Lower pierce tools 478 are mechanically, hydraulically, electrically or the like connected 482 to a piercetool driver mechanism 480. Piercetool driver mechanism 480 is synchronized to the controls which otherwise operate the entire pierce tool apparatus in a way that allows thepierce tool driver 480 to raise one or more lower piercetools 478 at the appropriate time so that bottom slots can be placed inworkpiece 238 simultaneously, or generally simultaneously, with the placement of upper slots inworkpiece 238 by one or moreupper pierce tools 380. - It is to be understood that the invention sought to be afforded protection hereby is not limited to the exact construction or embodiments illustrated and described herein, but that various changes and modification may be made without departing from the spirit and scope of the invention as defined in the following claims.
Claims (31)
1. A baffle, comprising:
a body portion having at least one side wall that forms a geometry that is adapted to register with a mating surface of a tube.
2. The baffle of claim 1 , wherein said side wall geometry includes a notch adapted to register with said mating member of said tube.
3. The baffle of claim 2 , wherein said body portion includes a first portion adapted to reside within a chamber of a tube and a second portion adapted to reside outside a chamber of a tube, wherein said second portion includes an eye.
4. The baffle of claim 3 , wherein said second portion includes an eye.
5. The baffle of claim 4 , wherein said eye is flanged.
6. The baffle of claim 3 , wherein said second portion includes two grip fingers.
7. The baffle of claim 3 , wherein said second portion includes a planar surface that is intersected by two spaced planar surfaces.
8. The baffle of claim 7 , wherein the two spaced planar surfaces are generally parallel.
9. The baffle of claim 4 , further including a rubber isolator having a male portion adapted to fit within said eye.
10. The baffle of claim 9 , wherein said isolator includes a contact region for contacting said body portion remote from said eye.
11. The baffle of claim 3 , wherein said first portion includes an opening adapted to allow fluid to pass through the opening.
12. The baffle of claim 3 , wherein said side wall geometry includes laterally spaced legs that are adapted to contact an outer surface of a tube.
13. The baffle of claim 12 , wherein said laterally spaced legs terminate into crimp tabs.
14. The baffle of claim 3 , wherein said second portion includes at least half of a high pressure manifold.
15. The baffle of claim 14 , wherein the half of the high pressure manifold is fabricated from stamped steel.
16. The baffle of claim 15 , wherein the half of the high pressure manifold incorporates at least one tubular element.
17. The baffle of claim 16 , wherein the half of the high pressure manifold incorporates at least two tubular elements.
18. A heat exchanger assembly, comprising:
a header tank having at least one baffle slot formed in a side wall portion of the header tank, wherein said slot includes at least one mating portion,
a first baffle including an inner baffle body portion adapted to be at least partially received within an inner chamber of the header tank through the baffle slot, wherein the inner baffle body portion forms at least one geometry that registers with the mating portion of the tank to retain the baffle within the slot.
19. The baffle of claim 18 , wherein said mating portion includes at least one tab member.
20. The baffle of claim 19 , wherein said at least one geometry includes a notch that registers with said at least one tab member.
21. The baffle of claim 20 , wherein said at least one tab is crimped into a portion of said notch.
22. The baffle of claim 18 , wherein said baffle body includes an outer baffle body portion residing outside of the inner chamber of said header tank, wherein said outer baffle body portion is adapted to engage at least one of a tubular member, a fastener, or a rubber isolator.
23. The baffle of claim 18 , wherein said baffle body includes an outer baffle body portion residing outside of the inner chamber of said header tank, wherein said outer baffle body portion forms at least half of a high pressure manifold.
24. The baffle of claim 18 , wherein said header tank includes a mating portion to engage and interlock with an adjacent member.
25. The baffle of claim 23 , wherein the adjacent member is a hood seal.
26. The baffle of claim 23 , wherein the adjacent member is an adjacent heat exchanger.
27. The baffle of claim 18 , wherein the baffle includes laterally spaced legs adapted to engage an outer surface of said header tank.
28. The baffle of claim 18 , further including a second baffle, wherein said second baffle is joined to said header tank in a spaced relation to said first baffle, and wherein said first and second baffles are attached to a tube that is in fluid communication with said header, wherein said first and second baffles perform a strain relief function to relieve strain induced at a point of connection between said header and said tube.
29. A tool for piercing a sidewall of a tube, comprising:
a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in an arcuate profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.
30. A tool for piercing a sidewall of a tube, comprising:
a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in sidewalls that have a concave profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.
31. A tool for piercing a sidewall of a tube, comprising:
a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in sidewalls that have a linearly tapering profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/293,572 US20060118287A1 (en) | 2004-12-02 | 2005-12-02 | Heat exchanger and method of making same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US63264104P | 2004-12-02 | 2004-12-02 | |
US11/293,572 US20060118287A1 (en) | 2004-12-02 | 2005-12-02 | Heat exchanger and method of making same |
Publications (1)
Publication Number | Publication Date |
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US20060118287A1 true US20060118287A1 (en) | 2006-06-08 |
Family
ID=36572912
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US11/293,572 Abandoned US20060118287A1 (en) | 2004-12-02 | 2005-12-02 | Heat exchanger and method of making same |
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US (1) | US20060118287A1 (en) |
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EP1914498A1 (en) * | 2006-10-18 | 2008-04-23 | Behr France Hambach S.A.R.L. | Flange, in particular for a heat exchanger |
WO2015071069A1 (en) * | 2013-11-18 | 2015-05-21 | Valeo Systemes Thermiques | Manifold for a heat exchanger |
US20180245861A1 (en) * | 2015-08-24 | 2018-08-30 | Mahle International Gmbh | Heat exchanger |
US10443944B2 (en) * | 2013-12-27 | 2019-10-15 | Daikin Industries, Ltd. | Heat exchanger and air conditioning device |
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Publication number | Priority date | Publication date | Assignee | Title |
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EP1914498A1 (en) * | 2006-10-18 | 2008-04-23 | Behr France Hambach S.A.R.L. | Flange, in particular for a heat exchanger |
WO2015071069A1 (en) * | 2013-11-18 | 2015-05-21 | Valeo Systemes Thermiques | Manifold for a heat exchanger |
FR3013436A1 (en) * | 2013-11-18 | 2015-05-22 | Valeo Systemes Thermiques | COLLECTOR FOR HEAT EXCHANGER |
KR20160084470A (en) * | 2013-11-18 | 2016-07-13 | 발레오 시스템므 떼르미끄 | Manifold for a heat exchanger |
CN105874296A (en) * | 2013-11-18 | 2016-08-17 | 法雷奥热系统公司 | Manifold for heat exchanger |
JP2017505421A (en) * | 2013-11-18 | 2017-02-16 | ヴァレオ システム テルミク | Manifold for heat exchanger |
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US10443944B2 (en) * | 2013-12-27 | 2019-10-15 | Daikin Industries, Ltd. | Heat exchanger and air conditioning device |
US20180245861A1 (en) * | 2015-08-24 | 2018-08-30 | Mahle International Gmbh | Heat exchanger |
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Legal Events
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AS | Assignment |
Owner name: QUASAR INDUSTRIES, INC., MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HIGGINS, KENNETH T.;REEL/FRAME:016975/0135 Effective date: 20051201 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |