Heat exchanger assembly

Abstract

A heat exchanger assembly has a first manifold, a second manifold in spaced and substantially parallel relationship with the first manifold and a plurality of flow tubes fluidly connecting the manifolds for passing refrigerant between the manifolds. The first manifold includes a header and tank which are joined by their longitudinal edges to form a cavity. The tank is extruded and has an outer wall and an inner partition wall with a plurality of apertures which define a distribution chamber within the cavity. The distribution chamber is fluidly connected to the cavity. A method of manufacturing a manifold generally includes the steps of extruding the tank, cutting the tank to a predetermined length, forming a plurality of apertures in the inner partition wall, forming a plurality of openings in the header, joining the tank and the header, and joining the end cap to the tank and header.

1 . A heat exchanger assembly) comprising:
 a first manifold having a tank and a header adjacent said tank and defining a hollow cavity;   a second manifold defining a hollow cavity and in spaced and substantially parallel relationship with said first manifold;   a plurality of flow tubes extending between and fluidly connecting said cavities of said manifolds for passing refrigerant between said manifolds; and   said tank having an outer wall defining a channel and an inner partition wall disposed within said channel adjacent said outer wall with said inner partition wall having a section integrally formed with a portion of said outer wall to define a distribution chamber disposed within said channel with said inner partition wall having a plurality of apertures fluidly connecting said distribution chamber with said cavity.   
   
   
       2 . An assembly as set forth in  claim 1  wherein said inner partition wall has a generally C-shaped cross-section. 
   
   
       3 . An assembly as set forth in  claim 1  wherein said outer wall includes a pair of opposed longitudinal edges each including a flange integral to and extending outward from said longitudinal edge forming a seat. 
   
   
       4 . An assembly as set forth in  claim 3  wherein said header includes a pair of longitudinal edges. 
   
   
       5 . An assembly as set forth in  claim 4  wherein said longitudinal edges of said header are adjacent said seats. 
   
   
       6 . An assembly as set forth in  claim 1  having at least one port in said first manifold and fluidly connected to at least one of said distribution chamber and said cavity. 
   
   
       7 . An assembly as set forth in  claim 6  wherein said port is adjacent at least one of said outer wall and an end cap of said first manifold. 
   
   
       8 . An assembly as set forth in  claim 7  wherein said at least one port further includes a coupler adjacent at least one of said outer wall and said end cap and fluidly connected to at least one of said distribution chamber and said cavity. 
   
   
       9 . An assembly as set forth in  claim 1  wherein said header includes a plurality of openings sized for accepting said plurality of flow tubes. 
   
   
       10 . An assembly as set forth in  claim 1  wherein said flow tubes are disposed within said cavity of said first manifold fluidly connecting said second manifold with said cavity of said first manifold. 
   
   
       11 . An assembly as set forth in  claim 1  wherein said inner partition wall includes a flattened ledge running a length of said inner partition wall adjacent said cavity with said plurality of apertures disposed within said ledge. 
   
   
       12 . A manifold comprising:
 a tank having an outer wall defining a channel;   a header mounted to said outer wall with said header and said outer wall defining a cavity; and   said tank having an inner partition wall disposed within said channel adjacent said outer wall with said inner partition wall having a section integrally formed with a portion of said outer wall to define a distribution chamber disposed within said channel with said inner partition wall having a plurality of apertures fluidly connecting said distribution chamber with said cavity.   
   
   
       13 . An assembly as set forth in  claim 12  wherein said inner partition wall has a generally C-shaped cross-section. 
   
   
       14 . An assembly as set forth in  claim 13  wherein said outer wall includes a pair of opposed flanges defining a pair of seats for said header. 
   
   
       15 . An assembly as set forth in  claim 14  wherein said header includes a pair of longitudinal edges abutting said seats. 
   
   
       16 . An assembly as set forth in  claim 15  having at least one port in said tank and fluidly connected to at least one of said distribution chamber and said cavity. 
   
   
       17 . An assembly as set forth in  claim 16  wherein said port is adjacent at least one of said outer wall and an end cap of said first manifold. 
   
   
       18 . An assembly as set forth in  claim 17  wherein said at least one port further includes a coupler adjacent at least one of said outer wall and said end cap and fluidly connected to at least one of said distribution chamber and said cavity. 
   
   
       19 . An assembly as set forth in  claim 12  wherein said header includes a plurality of openings. 
   
   
       20 . An assembly as set forth in  claim 12  wherein said inner partition wall includes a flattened ledge along a length of said inner partition wall facing said cavity with said plurality of apertures disposed within said inner ledge. 
   
   
       21 . A method of manufacturing a tank having an outer wall defining a channel, and an inner partition wall with a plurality of apertures, said method comprising the steps of:
 extruding the tank having the outer wall and the inner partition wall with the inner partition wall integrally connected to the outer wall to form a distribution chamber;   cutting the tank to a predetermined length; and   forming a plurality of apertures in the inner partition wall.   
   
   
       22 . A method of manufacturing a manifold having a tank with an outer wall defining a channel and an inner partition wall with a plurality of apertures, a header having a plurality of openings, and at least one end cap, said method comprising the steps of:
 extruding the tank having the outer wall and the inner partition wall with the inner partition wall integrally connected to the outer wall to form a distribution chamber;   cutting the tank to a predetermined length;   forming a plurality of apertures in the inner partition wall;   forming a plurality of openings in the header;   joining the tank and the header; and   joining the end cap to one end of the tank and the header.