Header extension to retain core cover and maintain constant compression on outer fins

Abstract

A heat exchanger and, in particular, a heat exchanger for a motor-vehicle air-conditioning system includes a manifold with apertures for heat exchanging tubes and projections at the ends of the manifold for retaining members. The projections are designed to maintain the position of the retaining members during manufacture of the heat exchanger so that defects are not introduced into the heat exchanger during production.

1 . A header for a heat exchanger, comprising: 
 a manifold;    wherein the manifold includes a plurality of apertures for tubes;    wherein each end of the manifold includes a plurality of projections for retaining an end member.    
   
   
       2 . The header of  claim 1 , wherein the plurality of projections at each end of the manifold form an opening in the end of the manifold.  
   
   
       3 . The header of  claim 2 , wherein the projections form an at least approximately semicircular opening at each end of the manifold.  
   
   
       4 . The header of  claim 1 , wherein at least one end of the manifold includes at least one portion that, in cooperation with the end member, allows fluid to flow between the manifold and the end member.  
   
   
       5 . The header of  claim 4 , wherein the at least one portion comprises a flat portion that does not follow the curvature of the end member.  
   
   
       6 . The header of  claim 5 , wherein the at least one portion comprises a plurality of flat portions that do not follow the curvature of the end member.  
   
   
       7 . The header of  claim 4 , wherein the at least one portion comprises at least one curved surface.  
   
   
       8 . The header of  claim 7 , wherein the at least one portion comprises a combination of curved and flat surfaces.  
   
   
       9 . The header of  claim 4 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       10 . A heat exchanger, comprising: 
 a first manifold;    a second manifold oriented substantially parallel to the first manifold;    a plurality of tubes extending between the first and second manifolds; and    an end member disposed adjacent to the plurality of tubes and extending between an end of the first manifold and an end of the second manifold,    wherein at least one end of the manifold includes a plurality of projections for retaining an end member.    
   
   
       11 . The heat exchanger of  claim 10 , wherein the plurality of projections at each end of the manifold form an opening in the end of the manifold.  
   
   
       12 . The heat exchanger of  claim 11 , wherein the projections form an at least approximately semicircular opening at each end of the manifold.  
   
   
       13 . The heat exchanger of  claim 10 , wherein at least one end of the manifold includes at least one portion that allows condensation to flow between the manifold and the end member.  
   
   
       14 . The heat exchanger of  claim 13 , wherein the at least one portion comprises a flat portion that does not follow the curvature of the end member.  
   
   
       15 . The heat exchanger of  claim 14 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       16 . The heat exchanger of  claim 13 , wherein the at least one portion comprises at least one curved surface.  
   
   
       17 . The heat exchanger of  claim 16 , wherein the at least one portion comprises a combination of curved and flat surfaces.  
   
   
       18 . The heat exchanger of  claim 13 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       19 . An automotive heating and cooling system, comprising: 
 devices for providing hot fluid and cold fluid;    a heat exchanger, which includes: 
 a first manifold;  
 a second manifold oriented substantially parallel to the first manifold;  
 a plurality of tubes extending between the first and second manifolds; and  
 an end member disposed adjacent to the plurality of tubes and extending between an end of the first manifold and an end of the second manifold,  
 wherein at least one end of the manifold includes a plurality of projections for retaining an end member.  
   
   
   
       20 . The automotive heating and cooling system of  claim 19 , wherein the plurality of projections at each end of the manifold form an opening in the end of the manifold.  
   
   
       21 . The automotive heating and cooling system of  claim 20 , wherein the projections form an at least approximately semicircular opening at each end of the manifold.  
   
   
       22 . The automotive heating and cooling system of  claim 19 , wherein at least one end of the manifold includes at least one portion that allows condensation to flow between the manifold and the end member.  
   
   
       23 . The automotive heating and cooling system of  claim 22 , wherein the at least one portion comprises a flat portion that does not follow the curvature of the end member.  
   
   
       24 . The automotive heating and cooling system of  claim 23 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       25 . The automotive heating and cooling system of  claim 22 , wherein the at least one portion comprises at least one curved surface.  
   
   
       26 . The automotive heating and cooling system of  claim 25 , wherein the at least one portion comprises a combination of curved and flat surfaces.  
   
   
       27 . The automotive heating and cooling system of  claim 22 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       28 . A motor vehicle, comprising: 
 a motor vehicle; and    a heat exchanger, which includes: 
 a first manifold;  
 a second manifold oriented substantially parallel to the first manifold;  
 a plurality of tubes extending between the first and second manifolds; and  
 an end member disposed adjacent to the plurality of tubes and extending between an end of the first manifold and an end of the second manifold,  
 wherein at least one end of the manifold includes a plurality of projections for retaining an end member.  
   
   
   
       29 . The motor vehicle of  claim 28 , wherein the plurality of projections at each end of the manifold form an opening in the end of the manifold.  
   
   
       30 . The motor vehicle of  claim 29 , wherein the projections form an at least approximately semicircular opening at each end of the manifold.  
   
   
       31 . The motor vehicle of  claim 28 , wherein at least one end of the manifold includes at least one portion that allows condensation to flow between the manifold and the end member.  
   
   
       32 . The motor vehicle of  claim 31 , wherein the at least one portion comprises a flat portion that does not follow the curvature of the end member.  
   
   
       33 . The motor vehicle of  claim 32 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.  
   
   
       34 . The motor vehicle of  claim 28 , wherein the at least one portion comprises at least one curved surface.  
   
   
       35 . The motor vehicle of  claim 34 , wherein the at least one portion comprises a combination of curved and flat surfaces.  
   
   
       36 . The motor vehicle of  claim 28 , wherein the at least one portion comprises a notch in an opening in the end of the manifold.