Brazed in place heat exchanger core window and method of making same

Abstract

A brazed in place heat exchanger core window is provided comprising a pair of coolant redirection boxes with coolant redirection tubes disposed therebetween. The coolant redirection boxes include a header and a pan, which are press fit to each other via overlapping legs. The headers include guides and slots to facilitate a press fit mating between the core tubes and each header, whereas the pans include ferrules to facilitate a press fit mating between the coolant redirection tubes and each pan. The core window is press fit to the heat exchanger core prior to brazing, and the entire core assembly, including the core window, may be brazed in a single operation.

1 . A heat exchanger core window located within a heat exchanger core comprising: 
 a first coolant redirection box for redirecting coolant within a heat exchanger core, the first coolant redirection box including a header and a pan;    a second coolant redirection box for redirecting coolant within a heat exchanger core, the second coolant redirection box including a header and a pan; and    a first coolant redirection tube disposed between the first and second coolant redirection boxes, wherein each header includes at least one leg that mates in a press fit relationship with at least one corresponding leg on each pan and wherein each pan includes at least one ferrule that mates in a press fit relationship with the first coolant redirected tube.    
   
   
       2 . The heat exchanger core window of  claim 1  further comprising a second coolant redirection tube disposed between the first and second coolant redirection boxes.  
   
   
       3 . The heat exchanger core window of  claim 2  wherein each header further includes a plurality of tube slots into which tubes of the heat exchanger core are inserted in a press fit relationship.  
   
   
       4 . The heat exchanger core window of  claim 3  wherein each header further includes a plurality of tube guides located between the plurality of tube slots.  
   
   
       5 . The heat exchanger core window of  claim 4  wherein each header further includes a plurality of tube guides located between the plurality of tube slots.  
   
   
       6 . The heat exchanger core window of  claim 1  wherein each header and each pan has the same number of legs.  
   
   
       7 . A heat exchanger core window located within a heat exchanger core comprising: 
 a first coolant redirection box for redirecting coolant within a heat exchanger core, the first coolant redirection box including a header and a pan;    a second coolant redirection box for redirecting coolant within a heat exchanger core, the second coolant redirection box including a header and a pan; and    a first coolant redirection tube disposed between the first and second coolant redirection boxes, wherein each header further includes at least one leg that mates in a press fit relationship with at least one corresponding leg on each pan and each header further includes a plurality of tube slots into which tubes of the heat exchanger core are inserted in a press fit relationship.    
   
   
       8 . The heat exchanger core window of  claim 7  wherein each header further includes a plurality of tube guides located between the plurality of tube slots.  
   
   
       9 . The heat exchanger core window of  claim 7  further comprising a second coolant redirection tube disposed between the first and second coolant redirection boxes.  
   
   
       10 . The heat exchanger core window of  claim 7  wherein each pan includes at least one ferrule that mates in a press fit relationship with the first coolant redirected tube.  
   
   
       11 . The heat exchanger core window of  claim 10  further comprising a second coolant redirection tube disposed between the first and second coolant redirection boxes.  
   
   
       12 . The heat exchanger core window of  claim 11  wherein each pan includes a first ferrule that mates in a press fit relationship with the first coolant redirected tube and a second ferrule that mates in a press fit relationship with the second coolant redirected tube.  
   
   
       13 . The heat exchanger core window of  claim 7  wherein each header and each pan has the same number of legs.  
   
   
       14 . A method for making a heat exchanger for use in a motor vehicle, the heat exchanger including a core window fabricated from a pair of headers, a pair of pans and at least one coolant redirection tube, the method comprising: 
 press fitting each header to each pan to form a pair of coolant redirection boxes;    press fitting a first coolant redirection tube to each of the coolant redirection boxes to define a core window;    press fitting the core window into the core of the heat exchanger; and    brazing the core window in place to the heat exchanger core.    
   
   
       15 . The method of  claim 14  wherein the step of brazing the core window is conducted simultaneously with brazing the heat exchanger core.  
   
   
       16 . The method of  claim 15  wherein brazing is conducted in a brazing oven.  
   
   
       17 . The method of  claim 14  wherein the core window is press fit into the core of the heat exchanger by press fitting coolant tubes of the core into tube slots on each header of each coolant redirection box.  
   
   
       18 . The method of  claim 14  wherein the first coolant redirection tube is press fit to each of the coolant redirection boxes by press fitting the ends of the first coolant redirection tubes into at least one ferrule located on each pan.  
   
   
       19 . The method of  claim 18  further comprising the step of press fitting a second coolant redirection tube to each of the coolant redirection boxes.  
   
   
       20 . The method of  claim 19  wherein the second coolant redirection tube is press fit to each of the coolant redirection boxes by press fitting the ends of the second coolant redirection tubes into a second ferrule located on each pan.