Heat exchanger assembly

Abstract

A heat exchanger assembly includes a first manifold having a first manifold body with an outer wall defining a cavity and an inner partition wall integrally formed with the outer wall to define a distribution chamber disposed within the cavity. A second manifold defines a hollow cavity and is in spaced and substantially parallel relationship with the first manifold. A plurality of flow tubes extend between and fluidly connect the cavities of the manifolds. The inner partition wall has a plurality of apertures fluidly connecting the distribution chamber with the cavity. A method of manufacturing the first manifold includes the steps of extruding the manifold body, forming a plurality of openings in the outer wall, forming a plurality of apertures in the inner partition wall, inserting a separator in the manifold body, and mounting the end cap to one end of the first manifold body.

1 . A heat exchanger assembly comprising:
 a first manifold having a first manifold body defining a hollow cavity;   a second manifold having a second manifold body 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 first manifold body having an outer wall defining said cavity and an inner partition wall disposed within said cavity 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 cavity 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 a length of said distribution chamber is defined by a length of said first manifold body. 
   
   
       4 . An assembly as set forth in  claim 3  wherein said distribution chamber is substantially parallel to said first manifold body. 
   
   
       5 . 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. 
   
   
       6 . An assembly as set forth in  claim 5  wherein said port is adjacent at least one of said outer wall and an end cap of said first manifold. 
   
   
       7 . An assembly as set forth in  claim 6  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. 
   
   
       8 . An assembly as set forth in  claim 1  wherein said outer wall includes a plurality of openings sized for accepting said plurality of flow tubes. 
   
   
       9 . An assembly as set forth in  claim 8  wherein said apertures in said inner partition wall are aligned with said openings in said outer wall. 
   
   
       10 . An assembly as set forth in  claim 8  wherein said flow tubes are mounted in said openings and disposed within said cavity of said first manifold fluidly connecting said second manifold to said cavity of said first manifold. 
   
   
       11 . An assembly as set forth in  claim 1  wherein said inner partition wall has a first thickness different than a second thickness of said outer wall. 
   
   
       12 . A manifold assembly comprising:
 an outer wall defining a hollow cavity; and   an inner partition wall disposed within said cavity 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 cavity 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 12  wherein a length of said distribution chamber is defined by a length of said outer wall. 
   
   
       15 . An assembly as set forth in  claim 14  wherein said distribution chamber is substantially parallel to said outer wall. 
   
   
       16 . An assembly as set forth in  claim 12  having at least one port in said first manifold 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 inlet 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 for introducing refrigerant into said first manifold. 
   
   
       19 . An assembly as set forth in  claim 12  wherein said outer wall includes a plurality of openings sized for accepting a plurality of flow tubes. 
   
   
       20 . An assembly as set forth in  claim 19  wherein said apertures in said inner partition wall are aligned with said openings in said outer wall. 
   
   
       21 . An assembly as set forth in  claim 12  wherein said inner partition wall has a first thickness different than a second thickness of said outer wall. 
   
   
       22 . A method of manufacturing a manifold having a manifold body with an outer wall defining a hollow cavity, an inner partition wall with a plurality of apertures and at least one end cap, said method comprising the steps of:
 extruding the manifold body having the outer wall and inner partition wall with the inner partition wall integrally connected to the outer wall to form a distribution chamber within the cavity;   cutting the manifold body to a pre-determined length;   forming a plurality of openings in the outer wall;   forming a plurality of apertures in the inner partition wall aligned with the openings in the outer wall;   inserting a separator into the manifold body; and   mounting the end cap to one end of the manifold body.