Heat exchanger having an improved baffle

Abstract

There is disclosed a heat exchanger for transferring heat between at least two fluids and a method for forming the heat exchanger. The heat exchanger preferably includes one or more end tanks, one or more inlets and outlets, one or more tubes, one or more fins, one or more bypasses, one or more improved baffles combinations thereof or the like. The improved baffles act as a baffle system, with advantages over multiple-piece double baffle system due to being assembled in one piece.

1 . A heat exchanger for an automotive vehicle having a heat exchanger tank and a baffle system, comprising: 
 a first end tank divided into a first portion and a second portion by a baffle in the first end tank;    a plurality of a first tubes in fluid communication with the first portion of the first end tank, the plurality of first tubes configured to have a first fluid flow therethrough;    a plurality of second tubes in fluid communication with the second portion of the first end tank;    the end tank further comprising a contact area having a deformation, perforation, slot or other shaped mating hole for a tab;    wherein:    i) the baffle system comprises at least one one-piece double baffle, the one-piece double baffle including at least two baffle profiles and at least one tab; and    ii) the one-piece double baffle is disposed within the end tank and is folded so that the one-piece double baffle has baffle profiles that are roughly parallel to each other.    
   
   
       2 . A heat exchanger as in  claim 1  wherein the one-piece double baffle comprises a tab at one section of its folded area and the end tank has a perforation, slot or shaped mating hole for insertion of the tab of the one-piece double baffle.  
   
   
       3 . A heat exchanger as in  claim 2  wherein the tab extends through the wall of end tank, thereby securing its position and forming a seal.  
   
   
       4 . A heat exchanger as in  claim 3 , wherein the seal formed is essentially leak-tight.  
   
   
       5 . A heat exchanger as in  claim 1 , wherein the at least one one-piece double baffle comprises at least two baffle profiles, each of the at least two baffle profiles having a common central portion and forming a chamber portion.  
   
   
       6 . A heat exchanger as in  claim 1  wherein the at least one tab has a relief means throughout its thickness.  
   
   
       7 . A heat exchanger as in  claim 2  wherein the end tank has a relief means at a point contiguous with the tab.  
   
   
       8 . A heat exchanger as in  claim 1  wherein the one-piece double baffle is formed from one continuous piece of material.  
   
   
       9 . A heat exchanger tank according to  claim 1  wherein the one-piece double baffle for separating fluid sections has perimeter walls that are approximately perpendicular to the tank wall surface.  
   
   
       10 . A heat exchanger as in  claim 9  wherein the perimeter walls of the baffle profiles have a common center area.  
   
   
       11 . A heat exchanger for an automotive vehicle having a heat exchanger tank and a baffle system, comprising: 
 a first end tank divided into a first portion and a second portion by a baffle the first end tank including;    a plurality of a first tubes in fluid communication with the first portion of the first end tank, the plurality of first tubes configured to have a first fluid flow therethrough;    a plurality of second tubes in fluid communication with the second portion of the first end tank, the plurality of second tubes configured to have a second fluid different from the first fluid, flow therethrough; and    the end tank further comprising at least one deformation, perforation, slot or other shaped mating hole for a tab;    wherein:    i) the baffle system comprises at least one one-piece double baffle, each one-piece double baffle including at least two baffle profiles and at least one tab, and,    ii) each one-piece double baffle is disposed within the end tank and is folded so that the one-piece double baffle has baffle profiles that are roughly parallel to each other.    
   
   
       12 . A heat exchanger as in  claim 11  wherein the one-piece double baffle comprises a tab at one section of its folded area and the end tank has a perforation, slot or shaped mating hole for insertion of the tab of the one-piece double baffle.  
   
   
       13 . A heat exchanger as in  claim 12  wherein the tab extends through the wall of end tank, thereby securing its position and forming a seal.  
   
   
       14 . A heat exchanger as in  claim 13 , wherein the seal formed is essentially leak-tight.  
   
   
       15 . A heat exchanger as in  claim 11 , wherein the at least one one-piece double baffle comprises at least two baffle profiles, each of the at least two baffle profiles having a common central portion or area and forming a chamber portion.  
   
   
       16 . A heat exchanger as in  claim 11  wherein the at least one tab has relief means throughout its thickness.  
   
   
       17 . A heat exchanger as in  claim 12  wherein the end tank has a relief means throughout its thickness at a point contiguous with the tab.  
   
   
       18 . A heat exchanger as in  claim 11  wherein the one-piece double baffle is formed from one continuous piece of material.  
   
   
       19 . A heat exchanger tank according to  claim 11  wherein the one-piece double baffle for separating fluid sections has perimeter walls that are approximately perpendicular to the tank wall surface.  
   
   
       20 . A heat exchanger as in  claim 19  wherein the perimeter walls of the baffle profiles have a common center portion or area.  
   
   
       21 . A method for making a heat exchanger tank assembly comprising: 
 manufacturing a one-piece double baffle comprising a tab at an area of insertion, fold or bend on the double baffle and with peripheral walls of the double baffle formed so that they form a central chamber;    providing a heat exchanger end tank which comprises a contact area comprising a deformation, perforation, slot or other shaped mating hole for insertion of the tab of the double baffle;    aligning the tab of the baffle and the end tank contact area so that the tab may be inserted into the contact area chamber;    inserting the one-piece double baffle in the end tank at the contact of the end tank; and    applying a sealing technique such that the double baffle remains in place after the assembly process and the completed heat exchanger assembly may be used in automotive applications.