Patent Application
20060070725
The subject invention relates to a heat exchanger assembly of the type having a tank at each end of a core with the tanks having open ends that are closed by caps.
Typically, a heat exchanger includes a core having opposite ends and sides defined by a plurality of fins and tubes extending between the opposite sides and between the opposite ends. A pair of header tanks are disposed at the opposite ends of the core and are in fluid communication with the tubes. The header tanks have open ends closed by end caps. A pair of reinforcement members are held to the header tanks for brazing by passing the terminal ends of the reinforcement members through the header tanks.
Various methods and designs have been used for holding reinforcement members to header tanks for brazing. Such methods and designs are disclosed in the U.S. Pat. No. 4,534,407 to Lardner; U.S. Pat. No. 5,236,042 to Kado; U.S. Pat. No. 5,289,873 to Ryan et al.; U.S. Pat. No. 6,179,050 to Dey et al.; U.S. Pat. No. 6,705,387 to Kokubunji et al.; the United States Patent Application No. 2003/0159816 to Kodumudi et al.; European Patent Specification No. EP0882940; and European Patent Application No. EP1030157.
There is a constant need in the area of an automotive industry for improvements in a heat exchanger designs to improve the connection between the header tank and the reinforcement member for holding each of the reinforcement members to the header tanks as the heat exchanger assembly is brazed.
A heat exchanger assembly for a motor vehicle includes a core having opposite sides and opposite ends with a plurality of fins extending between the opposite sides and a plurality of tubes extending between the opposite ends. First and second tanks have open ends and are disposed at the opposite ends of the core for fluid communication with the tubes. A plurality of tank caps close all of the open ends of the first and second tanks. A pair of core reinforcing members extend between terminal ends and are disposed along the opposite sides of the core. A tab and an opening for receiving the tab connect each of the tank caps to an adjacent terminal end of the reinforcing members. The tab has a head and a neck more narrower in width than the head with the opening smaller than the head for retaining the tab in the opening for connecting the reinforcing members to the tank caps as the heat exchanger is brazed.
An advantage of the present invention is to provide a heat exchanger assembly having a connection for holding to and preventing detachment of each of the core reinforcing members to the first and second tanks as a separation forces are applied thereto.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to
As shown in
The heat exchanger assembly 18 includes a plurality of tank caps, each generally indicated at 42. The tank caps 42 are configured for closing the opposite open ends of both of the first 30 and second 32 tanks at opposite terminal ends 22, 24 of the core 20. As illustrated in
As is customary in the art, a pair of a core reinforcing members, each generally shown at 52, extend along the opposite sides 26, 28 of the core 20. Each reinforcing member 52 presents terminal ends 54, 56 with each of the terminal ends 54, 56 presenting a pair of reversed interconnected first and second bends 58, 60 having an S-shaped configuration to engage the rim 48 of the adjacent tank cap 42. Each of the bends 58, 60 of the terminal ends 54, 56 are more narrow in width than the tank cap 42. A notch 62 is defined at each side of the terminal ends 54, 56 to define a bending joint between the second bend 60 at the intersection of the S-shaped configuration and the remainder of the reinforcing member 52. Each notch 62 assist to relieve stress applied to the core reinforcing member 52 thereby maintaining structural stability and braze clad surface contact as the heat exchanger assembly 18 is brazed. A gusset 64 is integral with and extends across the second bend 60 to provide structural support to each of the terminal ends 54, 56. Each of the core reinforcing members 52 includes a pair of spaced and parallel reinforcing flanges 70 extending upwardly and terminating short of the terminal ends 54, 56. The reinforcing flanges 70 extend upwardly along the sides of a flat bar. Each reinforcing member 52 consists of one homogenous material, namely a metal such as aluminum.
Referring to
As shown in
As appreciated by those skilled in the art, the aforementioned aluminum braze or brazing involves joining of components, such as, for example, the core 20 and the tanks 30, 32 prefabricated by having a brazing alloy (cladding) layer, i.e. outer layer (not shown) whose melting point is appreciably lower than that of the parent material (base alloy) base material, i.e. aluminum of the core 20 and the tanks 30, 32. The cladding, rolled onto the aluminum, is oriented adjacent to or in between the components to be joined, like, for example, the tank cap 42 and the tanks 30 or 32, whereby the heat exchanger assembly 18 is heated to a temperature where the cladding material melts and the parent material, i.e. aluminum does not. Upon cooling, the cladding forms a metallurgical bond between the joining surfaces of the components, i.e. the core 20, the first 30 and second 32 header tanks, the core reinforcing members 52, and the caps 42. The brazing process occurs in a furnace (not shown) as is well known in the art.
In automotive applications, the cladding is supplied via a thin layer on the base alloy. The base alloy provides the structural integrity while the low melting point cladding melts to form the brazed joints. The core 20, the first 30 and second 32 tanks, the core reinforcing members 52, and the tank caps 42, are formed from aluminum, aluminum alloy, and the like, and are integrally brazed in the furnace to provide the heat exchanger assembly 18 having high corrosion resistance and high heat conductivity characteristics.
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
