U.S. patent application number 10/194838 was filed with the patent office on 2002-12-05 for evaporator and method of making same.
Invention is credited to Abate, Gugliemo (William), Meyer, John Joseph.
Application Number | 20020179291 10/194838 |
Document ID | / |
Family ID | 23867492 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020179291 |
Kind Code |
A1 |
Abate, Gugliemo (William) ;
et al. |
December 5, 2002 |
Evaporator and method of making same
Abstract
An evaporator and method of making same includes a first end
tank, a second end tank spaced from and opposing the first end
tank, and a plurality of extruded fluid carrying tubes extending
between and in fluid communication with the first end tank and the
second end tank. The first end tank and the second end tank are
formed as stampings.
Inventors: |
Abate, Gugliemo (William);
(Dearborn, MI) ; Meyer, John Joseph; (Northville,
MI) |
Correspondence
Address: |
Bliss McGlynn, P.C.
Suite 600
2075 West Big Beaver Road
Troy
MI
48084
US
|
Family ID: |
23867492 |
Appl. No.: |
10/194838 |
Filed: |
July 12, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10194838 |
Jul 12, 2002 |
|
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09470402 |
Dec 22, 1999 |
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Current U.S.
Class: |
165/153 |
Current CPC
Class: |
F28F 9/0221 20130101;
F28F 2255/16 20130101; F28F 21/084 20130101; F28F 1/04 20130101;
F28F 9/262 20130101; F25B 39/028 20130101; F25B 39/02 20130101;
F28F 2255/08 20130101; F28F 2280/04 20130101; F28D 1/05358
20130101 |
Class at
Publication: |
165/153 |
International
Class: |
F28D 001/02 |
Claims
What is claimed is:
1. An evaporator comprising: a pair of joined first end tanks; a
pair of joined second end tanks spaced from and opposing said first
end tanks; a plurality of extruded fluid carrying tubes extending
between and in fluid communication with said first end tanks and
said second end tanks; and each of said first end tanks and said
second end tanks comprising a stamping, each of said first end
tanks having a pair of raised first bosses spaced laterally and
extending outwardly therefrom, each of said first bosses including
an aperture extending therethrough, and a mesh disposed in said
aperture and stamped into one of said first end tanks.
2. An evaporator comprising: a plurality of generally parallel
first end tanks, pairs of said first end tanks being joined
together in a face-to-face relationship, the pairs of said first
end tanks being joined together and aligned in a stack; a plurality
of generally parallel second end tanks, pairs of said second end
tanks, pairs of said second end tanks being joined together in a
face-to-face relationship, the pairs of said second end tanks being
joined together and aligned in a stack; a plurality of extruded
fluid carrying tubes, a pair of said tubes being spaced laterally
and extending between and in fluid communication with a joined pair
of said first end tanks and said second end tanks; a plurality of
fins attached to an exterior of said tubes; and each of the joined
pair of said first end tanks and said second end tanks comprising
stampings, each of the joined pair of said first end tanks having a
pair of raised bosses spaced laterally and extending outwardly
therefrom, and a mesh disposed over said aperture and stamped into
said first end tanks.
3. A method of making an evaporator comprising the steps of:
providing a plurality of generally parallel first end tanks formed
as stampings, pairs of the first end tanks being joined together in
a face-to-face relationship, the pairs of the first end tanks being
joined together and aligned in a stack; providing a plurality of
generally parallel second end tanks formed as stampings, pairs of
the second end tanks being joined together in a face-to-face
relationship, the pairs of the second end tanks being joined
together and aligned in a stack; providing a plurality of extruded
fluid carrying tubes extending between and in fluid communication
with opposed pairs of the first end tanks and the second end tanks;
providing a plurality of fins to be attached to an exterior of the
tubes and disposing the fins between the tubes; and joining the
fins and pairs of first end tanks and second end tanks together to
form the evaporator.
4. A method as set forth in claim 3 wherein said step of providing
the plurality of generally parallel first end tanks and second end
tanks includes the step of forming a flange extending axially to
form an opening.
5. A method as set forth in claim 4 wherein said step of providing
the plurality of generally parallel first end tanks and second end
tanks includes the step of forming a projection extending into the
opening.
6. A method as set forth in claim 4 including the step of inserting
an end of the tubes into the opening and locating the end of the
tubes relative to the opening via the projection.
7. A method as set forth in claim 3 wherein said step of joining
comprises brazing the first end tanks and second end tanks and
tubes and fins together.
8. A method of making an evaporator comprising the steps of:
stamping a plurality of generally parallel first end tanks and
forming a flange extending axially to form an opening; stacking
pairs of the first end tanks together in a face-to-face
relationship, the pairs of the first end tanks being aligned in a
stack; stamping a plurality of generally parallel second end tanks
and forming a flange extending axially to form an opening; stacking
pairs of the second end tanks together in a face-to-face
relationship, the pairs of the second end tanks being aligned in a
stack; providing a plurality of extruded fluid carrying tubes;
inserting an end of the tubes into the opening and extending the
tubes between and in fluid communication with opposed pairs of the
first end tanks and the second end tanks; providing a plurality of
fins and disposing the fins between the tubes; and brazing the
first end tanks and second end tanks and tubes and fins together to
form the evaporator.
9. A method as set forth in claim 8 including the step of forming a
projection extending into the opening.
10. A method as set forth in claim 9 including the step of locating
the end of the tubes relative to the opening via the projection.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a divisional of U.S. patent
application Ser. No. 09/470,402, filed Dec. 22, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to heat exchangers
and, more specifically, to an evaporator and method of making same
with stamped end tanks and extruded tubes for an air conditioning
system in a motor vehicle.
[0004] 2. Description of the Related Art
[0005] It is known to provide a heat exchanger such as an
evaporator for an air conditioning system in a motor vehicle. The
evaporator typically receives a fluid such as a refrigerant. The
evaporator normally includes a plurality of flow passages, which
may, for example, be constructed from flat plates or extruded,
tubes extending between opposite manifolds or end tanks. The
evaporator also includes a plurality of cooling fins disposed
between the flow passages. Evaporators are generally much thicker
than condensers, and thus require as manifolds or end tanks that
may be as wide or wider than fifty-five millimeters. One type of
evaporator, often referred to as an extruded tube evaporator,
includes a plurality of extruded tubes extending between the end
tanks to direct the refrigerant through a plurality of flow paths.
However, the end tanks typically used for extruded tube condensers
do not have the required strength due to the vastly increased
surface area and thus force present in such a wide heat exchanger.
Another type of evaporator, often referred to as a plate-fin
evaporator, includes a plurality of plates extending between the
end tanks to direct the refrigerant through a plurality of flow
paths. The end tanks are stamped by using a drawn-cup process.
[0006] Therefore, it is desirable to provide an evaporator with
stamped end tanks and extruded tubes. It is also desirable to
combine the benefits of stamped plate-fin evaporators and extruded
tube heat exchangers.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention is an evaporator
including a first end tank, a second end tank spaced from and
opposing the first end tank, and a plurality of extruded fluid
carrying tubes extending between and in fluid communication with
the first end tank and the second end tank. The first end tank and
the second end tank are formed as stampings.
[0008] One advantage of the present invention is that a new
evaporator and method of making same are provided for an air
conditioning system of a motor vehicle. Another advantage of the
present invention is that the evaporator has extruded tubes and
stamped end tanks. Yet another advantage of the present invention
is that the evaporator combines the benefits of stamped plate-fin
evaporators and extruded tube heat exchangers. Still another
advantage of the present invention is that the evaporator uses a
drawn-cup manifold, stamped such that, when assembled, accept
extruded tubes for passage of refrigerant. A further advantage of
the present invention is that the evaporator has the increased heat
transfer surface area of the extruded tube combined with the
strength and manufacturing flexibility of a drawn-cup manifold.
[0009] Other features and advantages of the present invention will
be readily appreciated, as the same becomes better understood,
after reading the subsequent description taken in conjunction with
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a fragmentary elevational view of an evaporator,
according to the present invention.
[0011] FIG. 2 is a sectional view taken along line 2-2 of FIG.
1.
[0012] FIG. 3 is a sectional view taken along line 3-3 of FIG.
2.
[0013] FIG. 4 is a sectional view taken along line 4-4 of FIG.
2.
[0014] FIG. 5 is a plan view of another embodiment, according to
the present invention, of the evaporator of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0015] Referring to the drawings and in particular FIG. 1, one
embodiment of a heat exchanger such as an evaporator 10, according
to the present invention, is shown for an air conditioning system
(not shown) in a motor vehicle (not shown). The evaporator 10
includes a pair of generally parallel manifolds or end tanks, first
end tank 12 and second end tank 14 spaced apart a predetermined
distance, pairs of which are joined together in a face-to-face
relationship to form a stack. The evaporator 10 also includes a
plurality of generally parallel, flat tubes 16 extending between
the end tanks 12,14 and conducting fluid such as a refrigerant
between them. The evaporator 10 includes oppositely disposed first
and second mounting plates 18 and 20 at ends of the stack. The
evaporator 10 further includes a fluid inlet 26 for directing fluid
into the evaporator 10 formed in the first mounting plate 18 and a
fluid outlet 28 for directing fluid out of the evaporator 10 formed
in the second mounting plate 20. The fluid inlet 26 and fluid
outlet 28 fluidly communicate with flow headers, generally
indicated at 22, formed by bosses 24 on each of the end tanks
12,14. The evaporator 10 also includes a plurality of convoluted or
serpentine fins 30 disposed between the tubes 16 and attached to an
exterior of each of the tubes 16. The fins 30 serve as a means for
conducting heat away from the tubes 16 while providing additional
surface area for convective heat transfer by air flowing over the
evaporator 10. It should be appreciated that the evaporator 10
could be used as a heat exchanger in other applications besides
motor vehicles.
[0016] Referring to FIGS. 2 through 4, the first and second end
tanks 12,14 extend laterally and are substantially planar or flat.
The first end tank 12 includes at least one, preferably a pair of
raised bosses 24 spaced laterally. The bosses 24 extend laterally
and vertically. Each boss 24 has an aperture 32 extending
therethrough. Each boss 24 also includes a flange 34 extending
axially and having a generally U-shaped cross-section to receive an
end of the tube 16. The flange 34 may include a projection 36 such
as a dimple extending outwardly and laterally to act as a positive
stop for locating the tube 16. The bosses 24 are stacked together
such that the apertures 32 are aligned to form the flow headers 22
to allow parallel flow of fluid such as refrigerant through the
tubes 16. The flanges 34 are also stacked together to form a slot
or opening 38 to receive one end of the tubes 16. The first end
tank 12 is made of a metal material such as aluminum having a
cladding on its inner and outer surfaces for brazing. The first end
tank 12 is also formed as a stamping using a drawn-cup stamping
process, which is conventional and known in the art.
[0017] The second end tank 14 may include at least one raised boss
40 extending laterally and vertically. The boss 40 acts as a solid
plate baffle. The second end tank 14 includes at least one,
preferably a pair of flanges 42 spaced laterally and extending
axially. Each of the flanges 42 has a generally U-shaped
cross-section to receive the other end of the tubes 16. Each flange
42 may include a projection 44 such as a dimple extending outwardly
and laterally to act as a positive stop for locating the tube 16.
The bosses 40 are stacked together to allow flow of fluid such as
refrigerant between the laterally spaced tubes 16. The flanges 42
are also stacked together to form a slot or opening 46 to receive
the other end of the tubes 16. The second end tank 14 is made of a
metal material such as aluminum having a cladding on its inner and
outer surfaces for brazing. The second end tank 14 is also formed
as a stamping using a drawn-cup stamping process, which is
conventional and known in the art.
[0018] The tubes 16 extend axially and are generally rectangular in
cross-sectional shape. Each of the tubes 16 has a passageway 48
extending axially therethrough to allow a fluid such as refrigerant
to pass therethrough. The tubes 16 are made of a metal material
such as aluminum having a cladding on its inner and outer surfaces
for brazing. The tubes 16 are formed as an extrusion using an
extrusion process, which is conventional and known in the art.
[0019] In operation, fluid such as refrigerant from the air
conditioning system enters the evaporator 10 through the fluid
inlet 26 on the first mounting plate 18. The refrigerant flows in
the flow header 22 of a first pair of joined first end tanks 12 and
flows through the passageway 48 in one of the tubes 16. The
refrigerant flows from the tube 16 and through a channel 49 of the
first pair of joined second end tanks 14 and through the passageway
48 of the other laterally spaced tube 16. The refrigerant flows
from the tube 16 and out of the other flow header 22 in the first
pair of joined end tanks 12. The refrigerant flow repeats this
U-shaped flow through each level of the evaporator 10 and exits the
evaporator 10 through the fluid outlet 28 on the second mounting
plate 20. It should be appreciated that refrigerant flows though
several tubes in parallel, with baffles (not shown) directing the
flow. It should also be appreciated that there are may different
options for circuiting refrigerant such that it goes through one
face of the core first, up the other face or u-flows down the core
and that baffles (not shown) may be located between joined pairs of
end tanks 12,14 to direct the refrigerant flow as desired.
[0020] Also, a method of making the evaporator 10, according to the
present invention, is shown. The method includes the step of
contacting a pair of first end tanks 12 with each other to form the
flow headers 22 and contacting opposed flanges 34 with each other
to form the openings 38. The method includes the step of brazing
the pair of first end tanks 12 by heating the first end tanks 12 to
a predetermined temperature to melt the brazing material to braze
the first end tanks 12 together. The pair of joined first end tanks
12 is then cooled to solidify the molten braze material to secure
the first end tanks 12 together. The method includes the step of
contacting a pair of second end tanks 14 with each other to form
the channel 49 therebetween and contacting opposed flanges 42 with
each other to form the openings 46. The method includes the step of
brazing the pair of second end tanks 14 by heating the second end
tanks 14 to a predetermined temperature to melt the brazing
material to braze the second end tanks 14 together. The pair of
joined second end tanks 14 is then cooled to solidify the molten
braze material to secure the second end tanks 14 together. The
method includes the step of inserting one end of the tube 16 in one
of the openings 38 of the first end tank 12 until the tube 16
contacts the projection 36. The method includes the step of
inserting the other end of the tube 16 in one of the openings 46 of
the second end tank 14 until the tube 16 contacts the projection
44. The method includes the step of inserting one end of another
tube 16 in the other of the openings 38 of the first end tank 12
until the tube 16 contacts the projection 36. The method includes
the step of inserting the other end of the tube 16 in the other of
the openings 46 of the second end tank 14 until the tube 16
contacts the projection 44. The method includes the step of
stacking the joined end tanks 12, 14 together and aligned in a
stack. The method includes the step of disposing fins 30 between
the tubes 16 and joining, such as by brazing, the fins 30, tubes 16
and the stack of the joined end tanks 12,14 together. The brazing
is accomplished by heating the end tanks 12,14, tubes 16, and fins
30 to a predetermined temperature to melt the brazing material to
braze the bosses 24,40 together. The stack of joined end tanks
12,14 is then cooled to solidify the molten braze material to
secure the bosses 24,40 and the tubes 16 and fins 30 together. The
method includes the step of connecting the first and second
mounting plates 18 and 20 to the brazed end tanks 12,14 to form the
evaporator 10. It should be appreciated that the end tanks 12,14
could be stacked and the tubes 16 and fins 30 assembled to the end
tanks 12,14 and brazing the assembly together at one time to form
the evaporator.
[0021] Referring to FIG. 5, another embodiment 110, according to
the present invention, is shown for the evaporator 10. Like parts
of the evaporator 10 have like reference numerals increased by one
hundred (100). In this embodiment, the evaporator 110 may include a
screen or mesh 150 stamped into the first end tank 112 in the
apertures 132 for improved flow distribution through the flow
headers 122. The mesh 150 is a generally rectangular grid forming a
plurality of apertures 152 having a generally rectangular shape to
allow fluid to pass therethrough. The mesh 150 and apertures 152
may have any suitable shape. The evaporator 110 is made and
operates similar to the evaporator 10. It should be appreciated
that the mesh 150 could be stamped into either one or both end
tanks 112,114.
[0022] The present invention has been described in an illustrative
manner. It is to be understood that the terminology, which has been
used, is intended to be in the nature of words of description
rather than of limitation.
[0023] Many modifications and variations of the present invention
are possible in light of the above teachings. Therefore, within the
scope of the appended claims, the present invention may be
practiced other than as specifically described.
* * * * *