Heat exchanger and method of making same

Abstract

A baffle having a body portion that includes at least one side wall. The side wall geometry is adapted to register with a mating surface of a tube. A heat exchanger assembly including a baffle, and a tool for forming a slot in a heat exchanger for accepting a baffle is also disclosed.

1 . A baffle, comprising: 
 a body portion having at least one side wall that forms a geometry that is adapted to register with a mating surface of a tube.    
   
   
       2 . The baffle of  claim 1 , wherein said side wall geometry includes a notch adapted to register with said mating member of said tube.  
   
   
       3 . The baffle of  claim 2 , wherein said body portion includes a first portion adapted to reside within a chamber of a tube and a second portion adapted to reside outside a chamber of a tube, wherein said second portion includes an eye.  
   
   
       4 . The baffle of  claim 3 , wherein said second portion includes an eye.  
   
   
       5 . The baffle of  claim 4 , wherein said eye is flanged.  
   
   
       6 . The baffle of  claim 3 , wherein said second portion includes two grip fingers.  
   
   
       7 . The baffle of  claim 3 , wherein said second portion includes a planar surface that is intersected by two spaced planar surfaces.  
   
   
       8 . The baffle of  claim 7 , wherein the two spaced planar surfaces are generally parallel.  
   
   
       9 . The baffle of  claim 4 , further including a rubber isolator having a male portion adapted to fit within said eye.  
   
   
       10 . The baffle of  claim 9 , wherein said isolator includes a contact region for contacting said body portion remote from said eye.  
   
   
       11 . The baffle of  claim 3 , wherein said first portion includes an opening adapted to allow fluid to pass through the opening.  
   
   
       12 . The baffle of  claim 3 , wherein said side wall geometry includes laterally spaced legs that are adapted to contact an outer surface of a tube.  
   
   
       13 . The baffle of  claim 12 , wherein said laterally spaced legs terminate into crimp tabs.  
   
   
       14 . The baffle of  claim 3 , wherein said second portion includes at least half of a high pressure manifold.  
   
   
       15 . The baffle of  claim 14 , wherein the half of the high pressure manifold is fabricated from stamped steel.  
   
   
       16 . The baffle of  claim 15 , wherein the half of the high pressure manifold incorporates at least one tubular element.  
   
   
       17 . The baffle of  claim 16 , wherein the half of the high pressure manifold incorporates at least two tubular elements.  
   
   
       18 . A heat exchanger assembly, comprising: 
 a header tank having at least one baffle slot formed in a side wall portion of the header tank, wherein said slot includes at least one mating portion,    a first baffle including an inner baffle body portion adapted to be at least partially received within an inner chamber of the header tank through the baffle slot, wherein the inner baffle body portion forms at least one geometry that registers with the mating portion of the tank to retain the baffle within the slot.    
   
   
       19 . The baffle of  claim 18 , wherein said mating portion includes at least one tab member.  
   
   
       20 . The baffle of  claim 19 , wherein said at least one geometry includes a notch that registers with said at least one tab member.  
   
   
       21 . The baffle of  claim 20 , wherein said at least one tab is crimped into a portion of said notch.  
   
   
       22 . The baffle of  claim 18 , wherein said baffle body includes an outer baffle body portion residing outside of the inner chamber of said header tank, wherein said outer baffle body portion is adapted to engage at least one of a tubular member, a fastener, or a rubber isolator.  
   
   
       23 . The baffle of  claim 18 , wherein said baffle body includes an outer baffle body portion residing outside of the inner chamber of said header tank, wherein said outer baffle body portion forms at least half of a high pressure manifold.  
   
   
       24 . The baffle of  claim 18 , wherein said header tank includes a mating portion to engage and interlock with an adjacent member.  
   
   
       25 . The baffle of  claim 23 , wherein the adjacent member is a hood seal.  
   
   
       26 . The baffle of  claim 23 , wherein the adjacent member is an adjacent heat exchanger.  
   
   
       27 . The baffle of  claim 18 , wherein the baffle includes laterally spaced legs adapted to engage an outer surface of said header tank.  
   
   
       28 . The baffle of  claim 18 , further including a second baffle, wherein said second baffle is joined to said header tank in a spaced relation to said first baffle, and wherein said first and second baffles are attached to a tube that is in fluid communication with said header, wherein said first and second baffles perform a strain relief function to relieve strain induced at a point of connection between said header and said tube.  
   
   
       29 . A tool for piercing a sidewall of a tube, comprising: 
 a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in an arcuate profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.    
   
   
       30 . A tool for piercing a sidewall of a tube, comprising: 
 a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in sidewalls that have a concave profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.    
   
   
       31 . A tool for piercing a sidewall of a tube, comprising: 
 a tool body having a rectangular cross section, wherein a first end of the tool when viewed in a front elevational profile terminates in sidewalls that have a linearly tapering profile and wherein the first end of the tool in a side elevational profile is defined by straight sides that angle toward one another terminating in an acute angle.