Heat exchanger manifold with formed corner joint

Abstract

The present invention relates to heat exchangers and heat exchanger assemblies, and, in particular, leak tight heat exchanger assemblies with coined or extruded corners. The present invention further provides for heat exchanger assemblies that improves leak tight features while maintaining or providing increased heat exchanger assembly structural integrity and durability. The present invention also provides for a method for making leak tight heat exchangers using various bonding processes.

1 . A heat exchanger assembly comprising: 
 a heat exchanger core composed of at least one tube and fin, and at least one tank or manifold, the tank or manifold, having a header portion with at least one opening, for an end of the at least one tube;    a first and second component portion having a planar surface within or near a corner, each portion having an extended planar bonding surface being closely aligned to each other;    wherein the second component portion bonding surface is mated with the first component portion planar bonding surface such that the second portion is locally deformed to create a transition area with the first component portion forming a bonding joint, said bonding joint bonded with a bonding material.    
   
   
       2 . A heat exchanger assembly as in  claim 1 , further having a third component portion having an extended planar bonding surface adjoined or affixed to the first component portion bonding surface, the bonding surfaces intersecting near terminal ends of the first and second component portions planar bonding surfaces, the terminal ends of the bonding surfaces being within or near a corner area.  
   
   
       3 . A heat exchanger assembly as in  claim 1  wherein the first and second component portion have terminal ends found within or near a corner, each portion having an extended planar bonding surface that closely follows or runs in parallel to each other.  
   
   
       4 . A heat exchanger assembly as in  claim 1  wherein the first and second component portion are formed in a “U” channel shape such that the second portion is more narrow and sets within and between the first portion.  
   
   
       5 . A heat exchanger assembly as in  claim 4  wherein the first and second component portion has symmetrically opposed formed transition corners.  
   
   
       6 . A heat exchanger assembly as in  claim 1  wherein the transition area forms a sharp corner.  
   
   
       7 . A heat exchanger assembly as in  claim 6  wherein the corner is a coined corner.  
   
   
       8 . A heat exchanger assembly as in  claim 1  wherein a part of the transition area forms a radius and a part of the transition area forms a sharp or coined corner.  
   
   
       9 . A heat exchanger assembly as in  claim 3  wherein the first or second component is made of material that has essentially the same metallurgical composition as the bonding material.  
   
   
       10 . A heat exchanger assembly as in  claim 4  wherein the first or second component is made of material that has essentially the same metallurgical composition as the bonding material.  
   
   
       11 . A heat exchanger assembly as in  claim 7  wherein the heat exchanger has a joint formed into a single assembly and bonded by an oven baking or brazing process.  
   
   
       12 . A heat exchanger assembly as is  claim 2  wherein the first, second and third component portions, meet in a coined corner.  
   
   
       13 . A heat exchanger assembly as in  claim 1 , wherein the first or the second component portion comprises a terminal end of a tube.  
   
   
       14 . A heat exchanger assembly as in  claim 1 , wherein the first or the second component portion comprises a tank.  
   
   
       15 . A heat exchanger assembly as in  claim 1 , wherein the first component portion comprises a terminal end of a tube and the second component portion comprises a tank.  
   
   
       16 . A heat exchanger assembly as in  claim 1 , wherein the first or the second component portion comprises a header.  
   
   
       17 . A heat exchanger assembly as in  claim 16 , wherein the heat exchanger is essentially leak tight at the area of the corner.  
   
   
       18 . A heat exchanger assembly as in  claim 13 , wherein the heat exchanger assembly is essentially leak tight at the corner area.  
   
   
       19 . A heat exchanger assembly comprising a manifold assembly having at least one tube and a header and, a heat exchanger core, wherein the manifold assembly has at least one coined corner and wherein the assembly is essentially leak tight at the area of the corner.  
   
   
       20 . A heat exchanger assembly as in  claim 18 , having at least one bond joint comprising a tube and header ferrule formed by the surfaces of the header wherein the assembly is brazed to form a leak tight joint at the area of the corner.  
   
   
       21 . A method of providing for a heat exchanger assembly with manifold and first and second component portions at the area of at least one corner by: 
 coining the manifold and portions in the area of the corner by press fitting or extrusion;    forming a bond joint at the area of the corner between surfaces at their mating areas;    brazing the heat exchanger assembly;    so that the heat exchanger assembly two component portions meet at a sharp angle to one another in at least one coined corner that is essentially leak tight after brazing.    
   
   
       22 . The method of  claim 21 , further comprising a third component portion, the third portion parallel to one of the first or second component portions, wherein coining occurs at an area that is naturally reinforced.