Heat exchange – Side-by-side tubular structures or tube sections – With manifold type header or header plate
Reexamination Certificate
2000-01-27
2001-04-17
Flanigan, Allen (Department: 3743)
Heat exchange
Side-by-side tubular structures or tube sections
With manifold type header or header plate
C165S175000, C029S890052
Reexamination Certificate
active
06216777
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to heat exchangers for motor vehicles and, more specifically, to a manifold and method of making same for a heat exchanger in a motor vehicle.
2. Description of the Related Art
It is known to provide a heat exchanger such as a condenser for an air conditioning system of a motor vehicle. The heat exchanger typically includes a plurality of U-shaped tubes having a fluid passing therethrough and a plurality of fins extending between the tubes. The number of U-shaped tubes depends on thermal capacity requirements of the heat exchanger. In order to connect these tubes together so that the fluid can flow through the tubes, manifolds are used having a series of openings corresponding to and mating with the ends of the tubes. The manifolds have an inlet port and an outlet port which circulate the fluid through the heat exchanger and then return the fluid to a remote location for subsequent recycling.
It is also known to fabricate manifolds as an extrusion using an extruding process. An example of such a method to make a manifold is disclosed in U.S. Pat. No. 5,190,101. In this patent, a manifold for a heat exchanger is fabricated by extruding a generally planar base member with a U-shaped channel disposed below a plane thereof and a pair of vertically depending walls projecting generally perpendicularly to the plane of the base member. The method includes forming a plurality of fluid conducting passageways in the base member and rolling the vertical depending walls toward a longitudinal center of the base member until the free ends of the walls are disposed in the channel of the base member to form fluid conduits. However, these extruded manifolds are relatively expensive to produce.
It is further known to fabricate manifolds as a stamping using a stamping process. An example of such a method to make a manifold is disclosed in U.S. Pat. No. 5,163,509. In this patent, a manifold assembly for a heat exchanger includes a first manifold and a second manifold. The first manifold has a first hollow conduit and a first plurality of apertures through the first conduit. The second manifold has a second hollow conduit and a second plurality of apertures through the second conduit. The manifold assembly includes at least one joining member between the first and second manifolds for joining the first manifold to the second manifold with the first conduit being side-by-side and adjacent the second conduit. The joining member includes a region of weakness for facilitating separation of the first and second manifolds. The manifold assembly is fabricated by stamping and bending a single elongate sheet metal strip.
Although the above manifolds have worked, they suffer from the disadvantage that the extruded manifolds are relatively costly to manufacture. Another disadvantage of the above manifolds is that the stamped manifolds have a portion extending above the plane of the fluid conduits. Yet another disadvantage of the above manifolds is that the stamped manifolds have a pair of seams that are brazed which may result in leakage of fluid if not brazed properly. Still another disadvantage of the above manifolds is that extruded manifolds have a U-shaped channel disposed below a plane of the base member, which is undesired. Therefore, there is a need in the art to provide a manifold for a heat exchanger of a motor vehicle that overcomes these disadvantages.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a manifold for a heat exchanger including a base member having a plurality of tubular members for connection to tubes of a heat exchanger. The manifold also includes a plurality of folds disposed between the tubular members to form a channel above a plane of the base member. The manifold includes a first side member extending from a side edge of the base member and a second side member extending from another side of the base member and opposing the first side member. The free ends of the first side member and the second side member are disposed in the channel and secured in place between the folds to define a first fluid conduit and a second fluid conduit.
Also, the present invention is a method of making a manifold for a heat exchanger. The method includes the steps of providing a generally planar sheet having a base member with a plurality of tubular members for connection to tubes of a heat exchanger. The method also includes the step of folding the sheet and forming a plurality of folds between the tubular members to form a channel above a plane of the base member. The method includes the step of folding lateral side edges of the sheet to form a first side member and a second side member opposing each other. The method further includes the step of folding free ends of the first side member and the second side member toward each other and disposing the free ends in the channel to define a first fluid conduit and a second fluid conduit.
One advantage of the present invention is that a stamped manifold for a heat exchanger such as a condenser is provided for an air conditioning system of a motor vehicle for condensing liquid refrigerant. Another advantage of the present invention is that the manifold uses a sheet that is stamped, folded and brazed to make a manifold. Yet another advantage of the present invention is that the manifold is stamped and folded and is less costly and more economical to manufacture than an extruded manifold.
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.
REFERENCES:
patent: 3368617 (1968-02-01), Rosman et al.
patent: 4770240 (1988-09-01), Dawson et al.
patent: 5163509 (1992-11-01), Dawson
patent: 5190101 (1993-03-01), Jalilevand et al.
patent: 59-104096 (1984-06-01), None
patent: 5/1896 (1993-01-01), None
Patel Ramchandra L
Rhodes Eugene E
Flanigan Allen
Shelton Larry I.
Visteon Global Technologies Inc.
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