Two-piece header/manifold construction for a heat exchanger having flattened tubes

Abstract

A header/manifold construction ( 14 ) is adapted to receive a plurality of flattened tube ends ( 42 ) in a heat exchanger ( 10 ) having a plurality of flattened tubes ( 12 ). The header/manifold construction ( 14 ) includes first and second pieces ( 20, 22 ) extending along a longitudinal axis ( 24 ). The first piece ( 20 ) has a C-shaped transverse cross defined by an elongate opening ( 44 ) extending along the longitudinal axis ( 24 ), with a plurality of tube slots ( 40 ) spaced along the axis ( 24 ) opposite from the opening ( 44 ). The second piece ( 22 ) has a T-shaped transverse cross section with two side legs ( 48, 50 ) extending from opposite sides of a center leg ( 46 ), with the legs ( 46, 48, 50 ) being bonded to surfaces of the first piece ( 20 ).

1 . A header/manifold construction adapted to receive a plurality of flattened tube ends in a heat exchanger having a plurality of flattened tubes; the header/manifold construction comprising:
 a first piece extending along a longitudinal axis and having a transverse cross section defined by a tube receiving wall, a side wall spaced opposite from the tube receiving wall, and two nose walls that are spaced opposite from each other to connect the tube receiving wall and the side wall, the tube receiving wall having a plurality of tube slots spaced along the longitudinal axis to receive the tube ends, the side wall being divided by an elongate opening extending along the longitudinal axis; and   a second piece extending along the longitudinal axis, the second piece having a transverse cross section defined by a center leg and a two side legs extending from opposite sides of the center leg; the center leg extending through the opening in the side wall and having an end surface bonded to an interior surface of the tube receiving wall, the end surface interrupted by a plurality of tube end clearance notches, each of the notches aligned with a corresponding one of the tube slots in the tube receiving wall, the two side legs bonded to an exterior surface of the side wall on opposite sides of the opening.   
   
   
       2 . The header/manifold construction of  claim 1  wherein the second piece has a mount flange extending away from the exterior surface of the side wall. 
   
   
       3 . The header/manifold construction of  claim 2  wherein the mount flange has an elongate slot extending along the longitudinal axis. 
   
   
       4 . The header/manifold construction of  claim 2  wherein the mount flange has a transverse opening extending therethrough. 
   
   
       5 . The header/manifold construction of  claim 1  wherein each of the tube end clearance notches is sized to provide a fluid flow gap between the center leg and a tube end received in the corresponding one of the tube slots. 
   
   
       6 . The header/manifold construction of  claim 1  wherein the end surface of the center leg is further interrupted by a plurality of tabs, each of the tabs extending through a tab receiving opening in the tube receiving wall, each of the tabs being deformed to engage the second piece with the first piece. 
   
   
       7 . The header/manifold construction of  claim 1  wherein the second piece is an extrusion. 
   
   
       8 . The header/manifold construction of  claim 1  wherein at least one of the first and second pieces is braze clad. 
   
   
       9 . The header/manifold construction of  claim 1  wherein the first piece is braze clad. 
   
   
       10 . The header/manifold construction of  claim 1  wherein the first piece is a formed piece of braze clad sheet metal. 
   
   
       11 . The header/manifold construction of  claim 1  wherein the center leg is bonded to opposite side edges of the opening in the side wall. 
   
   
       12 . The header/manifold construction of  claim 1  wherein the side legs are normal to the center leg. 
   
   
       13 . The header/manifold construction of  claim 1  wherein there is a port formed in the second piece, and further comprising a fluid connection bonded in said port. 
   
   
       14 . The header/manifold construction of  claim 1  wherein the side legs are configured to define a dovetail rail. 
   
   
       15 . The header/manifold construction of  claim 1  wherein the side legs are configured to define a dovetail slot. 
   
   
       16 . The header/manifold construction of  claim 1  wherein the side legs include a pair of flanges defining a longitudinal channel. 
   
   
       17 . A header/manifold construction adapted to receive a plurality of flattened tube ends in a heat exchanger having a plurality of flattened tubes; the header/manifold construction comprising:
 a first piece extending along a longitudinal axis and having a C-shaped transverse cross defined by an elongate opening extending along the longitudinal axis, the first piece having a plurality of tube slots space spaced along the longitudinal axis opposite from the opening;   a second piece extending along the longitudinal axis, the second piece having a T-shaped transverse cross section with two side legs extending from opposite sides of a center leg, the center leg extending through the elongate opening and having an end surface bonded to an interior surface of the first piece, the end surface interrupted by a plurality of tube end clearance notches, each of the notches aligned with a corresponding one of the tube slots in the tube receiving wall, the two side legs bonded to an exterior surface of the first piece on opposite sides of the opening.   
   
   
       18 . The header/manifold construction of  claim 17  wherein the second piece has a mount flange extending away from the exterior surface of the side wall. 
   
   
       19 . The header/manifold construction of  claim 18  wherein the mount flange has an elongate slot extending along the longitudinal axis. 
   
   
       20 . The header/manifold construction of  claim 18  wherein the mount flange has a transverse opening extending therethrough. 
   
   
       21 . The header/manifold construction of  claim 17  wherein each of the tube end clearance notches is sized to provide a fluid flow gap between the center leg and a tube end received in the corresponding one of the tube slots. 
   
   
       22 . The header/manifold construction of  claim 17  wherein the end surface of the center leg is further interrupted by a plurality of tabs, each of the tabs extending through a tab receiving opening in the tube receiving wall, each of the tabs being deformed to engage the second piece with the first piece. 
   
   
       23 . The header/manifold construction of  claim 17  wherein the second piece is an extrusion. 
   
   
       24 . The header/manifold construction of  claim 17  wherein at least one of the first and second pieces is braze clad. 
   
   
       25 . The header/manifold construction of  claim 17  wherein the first piece is braze clad. 
   
   
       26 . The header/manifold construction of  claim 17  wherein the first piece is a formed piece of braze clad sheet metal. 
   
   
       27 . The header/manifold construction of  claim 17  wherein the center leg is bonded to opposite side edges of the opening in the side wall. 
   
   
       28 . The header/manifold construction of  claim 17  wherein the side legs are normal to the center leg. 
   
   
       29 . The header/manifold construction of  claim 17  wherein there is a port formed in the second piece, and further comprising a fluid connection bonded in said port. 
   
   
       30 . The header/manifold construction of  claim 17  wherein the side legs are configured to define a dovetail rail. 
   
   
       31 . The header/manifold construction of  claim 17  wherein the side legs are configured to define a dovetail slot. 
   
   
       32 . The header/manifold construction of  claim 17  wherein the side legs include a pair of flanges defining a longitudinal channel.