Curled Manifold For Evaporator

Abstract

A manifold for use in a heat exchanger assembly and a method of forming the manifold is disclosed herein. The assembly includes an upper manifold defining an interior and having a upper top portion having an upper opening in the center of said upper top portion. A partition is inserted through the upper opening to define a plurality of chambers in the interior. The partition has a plurality of locking tabs and dimples that abut the upper top portion. The method starts with the step of forming the upper manifold defining an interior and having an upper top portion defining an upper opening in the center of the upper top portion. The method continues with the step of dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold and is finalized by joining the partition and the upper manifold through a snap fit.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to manifolds having multiple passages. More specifically, the invention relates to multi-pass manifolds.

[0003] 2. Description of the Prior Art

[0004] Air-cooling (or heating) cross-counter flow heat exchangers are often used in applications where space limitations restrict the surface are of the heat exchanger. Cross-counter flow heat exchangers typically include a plurality of stacked, assembled modules, with each module including a pair of spaced manifolds interconnected by a plurality of spaced and parallel tubes. The modules are stacked such that air flows in a direction perpendicular to the face of the heat exchanger, and air fins are disposed between adjacent pairs of tubes for transferring heat from the tubes to the passing air. U.S. Pat. No. 6,581,679 granted to Fisher discloses a heat exchanger having an upper manifold defining an interior and having an upper top portion and an upper lower portion. U.S. Pat. No. 5,582,239 granted to Tsunoda discloses an upper manifold having a partition.

[0005] There is a need for more efficient heat exchangers and methods of manufacturing the same.

SUMMARY OF THE INVENTION

[0006] In summary, the invention provides a manifold for use in a heat exchanger assembly and a method of forming the manifold. The method starts with the step of forming an upper manifold defining an interior and having an upper top potion defining an upper opening in the center of the upper top portion and an upper bottom portion defining a plurality of spaced upper tube slots. The method is finalized by the step of dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold and joining the partition and the upper manifold through a snap fit.

[0007] The apparatus includes a partition disposed in the upper manifold to define a plurality of chambers in the interior of the upper manifold. The partition has a plurality of spaced projections and a plurality of spaced upper recesses that extend longitudinally straight along a central axis for accepting the projections.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] 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:

[0009] FIG. 1 is a perspective view and exploded view of the exemplary embodiment of the invention;

[0010] FIG. 2 is a perspective view and exploded view of a second embodiment of the invention;

[0011] FIG. 3 is a front view of the upper manifold;

[0012] FIG. 4 is a cross-sectional view of the tubes taken along line 3-3 of FIG. 2;

[0013] FIG. 5 is a front view of the partition;

[0014] FIG. 6 is a perspective view of the partition of the second embodiment;

[0015] FIG. 7 is a perspective view of the upper manifold;

[0016] FIG. 8 is a perspective view of the upper manifold including the partition;

[0017] FIG. 9 is a perspective view of the upper manifold of a third embodiment; and

[0018] FIG. 10 is a perspective view of the upper manifold of the embodiment of FIG. 9.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

[0019] Referring to the Figures, like numerals indicate corresponding parts throughout the several views. Referring to FIGS. 1 and 2, a heat exchanger assembly is generally shown and includes an upper manifold 20 defining an interior. Referring to FIG. 3, the upper manifold 20 has an upper top portion 22 and an upper bottom portion 24. The upper top portion 22 has a semi-circular or curved shape and an upper opening 26 in the center of the upper top portion 22. Referring again to FIG. 2, a lower manifold 28 is spaced and parallel from the upper manifold 20. The upper bottom portion 24 of the upper manifold 20 defines a plurality of spaced upper tube slots 30 and the lower manifold 28 defines a plurality of spaced lower tube slots 32.

[0020] A plurality of tubes 34, each having flat sides 36 and round ends 68, extend between upper and lower tube ends 38, 40 in the upper and lower tube slots 30, 32. Each of the tubes 34 extend parallel and spaced from one another and define a plurality of air or refrigerant passages 42 there between. The tube slots 30, 32 include a plurality of rows of tube slots 30, 32 one on each side of said central axis A and the tubes 34 include a plurality of rows of tubes 34 one on each side of said central axis A and are disposed in the tube slots 30, 32.

[0021] Referring to FIG. 2, an air fin 46 is disposed between and is brazed to the flat sides 36 of the tubes 34. The air fin 46 extends between the upper and lower manifolds 20, 28 for dissipating heat from the tubes 34. Referring to FIG. 1, an end cap 44 is disposed on each end of the manifolds 20, 28. The lower manifold 28 further defines an interior and has a lower top portion 60 and a lower bottom portion 62

[0022] A partition 48 is disposed in the upper manifold 20 and defines a plurality of chambers 50 in the interior of the upper manifold 20. The partition 48 has a plurality of spaced projections 58. The upper bottom portion 24 has a plurality of spaced upper recesses 64 extending longitudinally straight for accepting the projections 58. The partition 48 defines a plurality of holes 56 for conveying refrigerant through the manifold. The holes 56 may be gradient as shown in FIG. 1, or consistent, as they extend along the partition 48. The holes 56 may also be any shape or frequency to facilitate communication between the first and second passes of the manifolds 20, 28.

[0023] In a second embodiment and as shown in FIGS. 2, 5, 6, 9, and 10, the partition 48 has a plurality of spaced and alternating locking tabs 52 disposed on the opposite end as the projections 58 for abutting the top portion at the exterior of the upper manifold 20. The partition 48 also has a plurality of spaced dimples 54 for abutting the top portion 22, 60 at the interior of the upper manifold 20 to form a snap fit through the opening 26. The dimples 54 have a ramp-like shape when looking at a plane normal to the partition 48 and as shown in FIG. 5. The upper top portion 22 is made of a material that may bend to allow the dimple 54 of the partition 48 to be inserted through the opening 26. Further, the upper top portion 22 and the lower top portion 24 are a single piece forming the upper manifold 20.

[0024] When applied to an Inlet/Outlet manifold, the partition 48 prevents the refrigerant from flowing from one chamber 50 to another. When applied to a return manifold, the partition 48 includes holes 56 that allow the refrigerant to flow from one chamber 50 to the other. The partition 48 also acts as a stiffener and provides additional strength.

[0025] Referring to FIGS. 9 and 10, a third embodiment includes a four pass heat exchanger. The top portions 22, 60 of the manifolds 20, 28 have at least one slot 66 extending from the side opposite of the locking tabs 52. At least one separator 70 is included for insertion into the slots 66 in the top portions 22, 60, dividing the interior of the manifolds 20, 28 into more than two chambers 50.

[0026] The invention also includes a method of forming a manifold for use in a heat exchanger assembly. The method starts with the step of forming an upper manifold 20 defining an interior and having an upper top portion 22 defining an upper opening 26 in the center of the upper top portion 22 and an upper bottom portion 24 defining a plurality of spaced upper tube slots 30. The method continues with the step of dividing the upper manifold 20 to define a plurality of chambers 50 in the interior of the upper manifold 20. The method proceeds with the step of joining the partition 48 and the upper manifold 20. The joining step includes inserting projections 58 from the partition 48 into spaced recesses 64 defined by the bottom portion of the manifold. The joining step also includes projecting a dimple 54 from the partition 48 and providing an opening 26 in the upper top portion 22 and elastically forming the opening 26 of the upper top portion 22 and sliding the dimple 54 through the opening 26, creating a snap fit.

[0027] The method continues with the step of permanently fixing the partition 48 to the upper manifold 20. The method proceeds with the step of permanently fixing at least one locking tab 52 disposed on the partition 48 to the exterior of the upper top portion 22 of the upper manifold 20 wherein the permanent fixing is further defined as brazing. The method proceeds with the step of forming a plurality of tubes 34 extending between upper and lower tube ends 38, 40 and defining a plurality of air or refrigerant passages 42. The method continues with inserting the upper tube ends 38 of each tube 34 into one of the upper tube slots 30 of the upper manifold 20 to establish fluid communication between the passages 42 of the tubes 34 and the chambers 50 of the upper manifold 20.

[0028] The method continues with the step of forming a lower manifold 28 defining an interior and having an lower top portion 60 defining and a lower bottom portion 62 defining a plurality of spaced upper tube slots 30 aligning with the upper tube slots 30. The method further continues with the step of inserting the lower tube end 40 of each of the tubes 34 into the corresponding lower tube slot 32 of the lower manifold 28 to establish fluid communication between the passages 42 of each tube 34 and the lower manifold 28.

[0029] The method proceeds with the step of forming an air fin 46 between adjacent tubes 34 to dissipate heat from the tube 34. The method is completed with the step of inserting a separator 70 into the top portions 22, 60 for dividing the interior of the manifolds 20, 28 into more than two chambers 50.

[0030] It is to be understood that "upper" and "lower" as used in the present application are arbitrary, inasmuch as a heat exchanger in accordance with the present invention can be oriented in different directions. Therefore, "upper" and "lower" should be understood to be used with reference to the orientation of the manifolds 20, 28 and tubes 34 as shown in the drawings herein, and is not limiting the orientation of the manifolds 20, 28 or tubes 34 in actual use.

[0031] 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 teaching 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.

Claims

1. A manifold assembly for a heat exchanger: an upper manifold defining an interior and having a upper top portion and an upper bottom portion; said upper top portion having an upper opening in the center of said upper top portion; a partition for insertion through said upper opening for defining a plurality of chambers in the interior of said upper manifold; and said partition having a plurality of spaced projections and said upper bottom portion having a plurality of spaced upper recesses extending longitudinally straight along a central axis for accepting said projections.

2. An assembly as set forth in claim 1 including a plurality of dimples for abutting said upper top portion at the interior of said upper manifold to form a snap fit through said opening.

3. An assembly as set forth in claim 2 wherein said partition has a plurality of spaced and alternating locking tabs for abutting said upper top portion at the exterior of said upper manifold.

4. The assembly as set forth in claim 3 wherein said dimple has a ramp-like shape when looking at a plane normal to said partition.

5. The assembly as set forth in claim 1 wherein said upper bottom portion of said upper manifold define a plurality of spaced upper tube slots.

6. The assembly as set forth in claim 5 including a plurality of tubes extending between upper and lower tube ends and parallel and spaced from one another for defining a plurality of air passages there between and said upper tube end of each of said tubes is disposed in one of said upper tube slots of said upper manifold.

7. The assembly as set forth in claim 6 including a lower manifold extending in spaced and parallel relationship with said upper manifold and defining a plurality of lower tube slots being spaced and aligned with said upper tube slots and said lower tube ends of each of said tubes extending into corresponding said lower tube slots of said lower manifold to establish fluid communication between said passages of said tubes and said lower manifold.

8. The assembly as set forth in claim 7 wherein said tube slots include a plurality of rows of tube slots one on each side of said central axis.

9. The assembly as set forth in claim 8 wherein said tubes include a plurality of tube rows one on each side of said central axis and are disposed in said tube slots.

10. The assembly as set forth in claim 9 wherein said lower manifold defines an interior and has a lower top portion and a lower bottom portion and wherein said top portions of said manifolds have at least one slot.

11. The assembly as set forth in claim 10 including at least one separator for insertion into said slots in said top portions of said manifolds to divide the interior of said manifolds into more than two chambers.

12. The assembly as set forth in claim 11 wherein said top portions have a curved shape.

13. The assembly as set forth in claim 12 wherein said tubes have a cross-section defining flat sides and round ends.

14. The assembly as set forth in claim 13 including an air fin disposed between and brazed to of said tubes and extending between said upper and lower manifolds for dissipating heat from said tubes.

15. The assembly as set forth in claim 7 including an end cap disposed on each end of said manifolds.

16. The assembly as set forth in claim 1 wherein said partition defines a plurality of holes for conveying refrigerant through said manifold.

17. A method of forming a manifold assembly for a heat exchanger including the steps of: forming an upper manifold defining an interior and having an upper top potion defining an upper opening in the center of the upper top portion and an upper bottom portion defining a plurality of spaced upper tube slots; dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold; and joining the partition and the upper manifold.

18. The method as set forth in claim 17 further including the step of: wherein said joining step includes projecting a dimple from the partition and providing an opening in the upper top portion and elastically forming the opening by sliding the dimple through the opening.

19. The method as set forth in claim 18 further including the step of: permanently fixing at least one locking tab disposed on the partition to the exterior of the upper top portion of the upper manifold wherein the permanent fixing is further defined as brazing.

20. The method as set forth in claim 19 further including the step of: forming a plurality of tubes extending between upper and lower tube ends and defining a plurality of air passages there between.

21. The method as set forth in claim 20 further including the step of: inserting the upper tube end of each tube into one of the upper tube slots of the upper manifold and to establish fluid communication between the passages of the tubes and the chambers of the upper manifold.

22. The method as set forth in claim 21 further including the step of: forming a lower manifold defining an interior and having an upper top potion defining and an upper bottom portion defining a plurality of spaced upper tube slots aligning with the upper tube slots;

23. The method as set forth in claim 22 further including the step of: inserting the lower tube end of each of the tubes into the corresponding lower tube slot of the lower manifold to establish fluid communication between the passages of each tube and the lower manifold.

24. The method as set forth in claim 23 further including the step of: forming an air fin between adjacent tubes to dissipate heat from the tube.

25. The method as set forth in claim 24 further including the step of: inserting a separator into the top portions for dividing the interior of the manifolds into more than two chambers.

26. A heat exchanger assembly comprising: an upper manifold defining an interior and having an upper top portion and an upper bottom portion; said top portion having a curved shape and an upper opening in the center of said upper top portion; a lower manifold being spaced and parallel from said upper manifold; said upper bottom portion of said upper manifold defining a plurality of spaced upper tube slots; said lower manifold defining a plurality of spaced lower tube slots; a plurality of tubes having flat sides and extending between upper and lower tube ends in said upper and lower tube slots and parallel and spaced from one another for defining a plurality of air passages there between; said tube slots including a plurality of rows of tube slots one on each side of said central axis; said tubes include a plurality of tube rows disposed in said tube slots to define a plurality of passages; an air fin disposed between and brazed to said flat sides of said tubes and extending between said upper and lower manifolds for dissipating heat from said tubes; said lower manifold defining an interior and having a lower top portion and a lower bottom portion and said top portions of said manifolds having at least one slot; at least one separator for insertion into said slots in said top portions to divide the interior of said manifolds into more than two chambers; an end cap disposed on each end of said manifolds; a partition disposed in said upper manifold to define a plurality of chambers in the interior of said upper manifold; said partition having a plurality of spaced and alternating locking tabs for abutting the top portion at the exterior of said upper manifold and a plurality of spaced dimples for abutting the top portion at the interior of said upper manifold to form a snap fit through said opening; said dimples having a ramp-like shape when looking at a plane normal to said partition; and said partition having a plurality of spaced projections and said upper bottom portion having a plurality of spaced upper recesses extending longitudinally straight for accepting said projections; and said partition defines a plurality of holes for conveying refrigerant through said manifold.

27. The assembly as set forth in claim 26 wherein said tubes including a plurality of tube rows one on each side of said central axis.