Modular manifolds for heat exchangers

Abstract

Modular manifolds for heat exchangers are disclosed with a primary tube disposed alongside a heat exchanger with a port disposed adjacent to ports of the heat exchanger. A manifold block is provided with a port mounted to the primary tube for fluid communication with the primary tube. The manifold block includes a plurality of back extruded ports for direct communication with the ports of the heat exchanger. Additionally, a method is disclosed for manufacturing a modular manifold for heat exchangers.

1 . A modular manifold for a heat exchanger comprising: 
 a primary tube disposed alongside a heat exchanger, the primary tube having a port disposed adjacent to at least a pair of ports of the heat exchanger; and    a manifold block having a first port mounted to the primary tube port for fluid communication with the primary tube, the manifold block having at least a pair of back extruded ports for direct fluid communication with the at least a pair of ports of the heat exchanger.    
   
   
       2 . The modular manifold of  claim 1  wherein the manifold first port has an inner diameter that is greater than that of either of the at least a pair of back extruded ports of the manifold block.  
   
   
       3 . The modular manifold of  claim 1  wherein the first port of the manifold is formed axially into the manifold block and the at least a pair of back extruded ports are generally perpendicular to the first port of the manifold block.  
   
   
       4 . The modular manifold of  claim 1  wherein the heat exchanger is a component within an air conditioning cycle.  
   
   
       5 . The modular manifold of  claim 1  wherein the heat exchanger further comprises air conditioning coils.  
   
   
       6 . The modular manifold of  claim 1  wherein the manifold block further comprises a second port formed axially into the manifold block.  
   
   
       7 . The modular manifold of  claim 6  wherein the second axial port has an inner diameter that is less than an inner diameter of the first axial port.  
   
   
       8 . The modular manifold of  claim 6  further comprising a second manifold block having a first port mounted to the second axial port of the first manifold block for fluid communication with the first manifold block.  
   
   
       9 . The modular manifold of  claim 8  wherein the first port of the second manifold block has an inner diameter that is less than that of the first port of the first manifold block.  
   
   
       10 . The modular manifold of  claim 8  further comprising an intermediate tube in fluid communication with the second axial port of the first manifold block and the first port of the second manifold block for fluid communication between the first and second manifold blocks.  
   
   
       11 . The modular manifold of  claim 8  wherein the second manifold block has a closed second end spaced apart and opposed from the first port.  
   
   
       12 . The modular manifold of  claim 8  wherein the second manifold block has at least a pair of back extruded ports for direct fluid communication with at least a second pair of ports of the heat exchanger.  
   
   
       13 . The modular manifold of  claim 12  wherein the at least a pair of back extruded ports of the second manifold block are arranged relative to the second manifold block generally corresponding to an arrangement of the at least a pair of back extruded ports of the first manifold block.  
   
   
       14 . The modular manifold of  claim 1  wherein the at least a pair of back extruded ports each further comprise a riser extending from the first manifold block.  
   
   
       15 . The modular manifold of  claim 14  further comprising at least a pair of rings formed from a material having a melting temperature less than that of the primary tube, the first manifold block, and the heat exchanger.  
   
   
       16 . The modular manifold of  claim 15  wherein each of the at least a pair of rings is displaced about one of the at least a pair of risers, and the heat exchanger and manifold are heated to a temperature greater than the melting temperature of the at least a pair of rings so that the rings melt and join the manifold to the heat exchanger.  
   
   
       17 . The modular manifold of  claim 16  wherein each of the at least a pair of rings is press fit about one of the at least a pair of risers.  
   
   
       18 . A method for manufacturing a manifold for a heat exchanger comprising: 
 forming a primary tube to approach a series of ports on a heat exchanger;    forming a series of riser ports on a manifold block that are sized to cooperate with a portion of the series of ports on the heat exchanger;    mounting the manifold block on the primary tube;    mounting the manifold block risers on the portion of the series of ports on the heat exchanger;    forming an intermediate tube to extend from the manifold block to a remaining portion of the series of ports on the heat exchanger;    mounting the intermediate tube to the manifold block;    forming a series of riser ports on a second manifold block that are sized to cooperate with the remaining portion of the series of ports on the heat exchanger;    mounting the second manifold block on the intermediate tube; and    mounting the second manifold block risers on the remaining portion of the series of ports on the heat exchanger.    
   
   
       19 . The method of  claim 18  further comprising: forming a plurality of rings from a material having a melting temperature less than that of the primary tube, the intermediate tube, the manifold blocks and the heat exchanger; 
 mounting each of the plurality of rings on one of the risers of the manifold blocks;    heating the manifold and heat exchanger to a temperature greater than the melting temperature of the rings; and    cooling the manifold and heat exchanger.    
   
   
       20 . A modular manifold for a heat exchanger comprising: 
 a primary tube disposed alongside a heat exchanger, the primary tube having a port disposed adjacent to at least a pair of ports of the heat exchanger; and    a first manifold block having a first port formed axially therein, the first port being mounted to the primary tube port for fluid communication with the primary tube, the first manifold block having at least a pair of back extruded ports formed generally perpendicular to the first port for direct fluid communication with the at least a pair of ports of the heat exchanger, the back extruded ports each having an inner diameter less than that of the first port, the first manifold block having a second port formed axially therein, the second port having an inner diameter less than that of the first port and greater than that of the back extruded ports;    an intermediate tube in fluid communication with the second axial port of the first manifold block, the intermediate tube having an inner diameter less than that of the primary tube, the intermediate tube having a port disposed adjacent to at least a second pair of ports of the heat exchanger; and    a second manifold block having a first port formed axially therein, the first port having an inner diameter that is less than that of the first port of the first manifold block, the first port of the second manifold block being mounted to the intermediate tube for fluid communication with the intermediate tube, the second manifold block having at least a pair of back extruded ports for direct fluid communication with the at least a second pair of ports of the heat exchanger, the at least a pair of back extruded ports of the second manifold block being arranged relative to the second manifold block generally corresponding to an arrangement of the at least a pair of back extruded ports of the first manifold block.