Manifolds and manifold connections for heat exchangers

Abstract

Manifolds and manifold connections for heat exchangers are disclosed. One embodiment includes an elongate tubular body with a central cavity. The body has an elongate retainer formed therealong. An attachment member is received by the retainer and an insert is retained between the tubular body and the attachment. The insert is formed from a material having a melting temperature less than that of the tubular body and the attachment member. The manifold may be heated to a temperature greater than the melting temperature of the insert material and subsequently cooled so that the insert joins the attachment member to the body.

1 . A manifold for a heat exchanger comprising: 
 an elongate tubular body with a central cavity formed therethrough, the tubular body having an elongate retainer formed at least partially therealong;    an attachment member having an end received by the retainer; and    an insert retained between the tubular body and the attachment member, the insert being formed from a material having a melting temperature less than that of the tubular body and the attachment member.    
   
   
       2 . The manifold of  claim 1  wherein the manifold is heated to a temperature greater than the melting temperature of the insert material and subsequently cooled so that the insert joins the attachment member to the tubular body.  
   
   
       3 . The manifold of  claim 1  wherein the tubular body has at least one port formed therethrough, the insert has an aperture sized relative to the port and generally aligned with the port, and the attachment member further comprises a second tubular body having a distal end disposed through the insert aperture and the port for fluid communication with the tubular body central cavity.  
   
   
       4 . The manifold of  claim 1  wherein the tubular body has at least one port formed therethrough, the insert has an aperture sized relative to the port and generally aligned with the port, and the attachment member further comprises a fitting having a distal end disposed through the insert aperture and the port for fluid communication with the tubular body central cavity.  
   
   
       5 . The manifold of  claim 1  wherein the attachment member further comprises a bracket for fastening the manifold to another component.  
   
   
       6 . The manifold of  claim 1  wherein the tubular body and the retainer are coextruded.  
   
   
       7 . The manifold of  claim 1  wherein the retainer is formed along the length of the tubular body.  
   
   
       8 . The manifold of  claim 1  wherein the insert has a contour formed along the length of the insert that is sized to match a contour of the tubular body.  
   
   
       9 . The manifold of  claim 1  wherein the tubular body is formed from an aluminum alloy having an American National Standards Institute (ANSI) designation of 3003 and the insert is formed from an aluminum alloy having an ANSI designation of 4047.  
   
   
       10 . The manifold of  claim 1  wherein the retainer further comprises a pair of gibs in spaced opposition.  
   
   
       11 . The manifold of  claim 10  wherein the insert is at least partially displaced beneath the pair of gibs.  
   
   
       12 . The manifold of  claim 10  wherein the tubular body has a pair of recesses formed along its length, each displaced beneath the pair of gibs for facilitating flow of insert material after the insert has reached the melting temperature.  
   
   
       13 . The manifold of  claim 10  wherein the gibs are deformed to retain the insert.  
   
   
       14 . The manifold of  claim 10  wherein the insert has an interference fit between the gibs and the tubular body.  
   
   
       15 . A manifold for a heat exchanger comprising: 
 an elongate tubular body with a central cavity formed therethrough and at least one port formed transversely through the tubular body;    an elongate retainer formed at least partially along the tubular body adjacent to the at least one port;    an insert formed from a material having a melting temperature less than that of the tubular body, the insert having an aperture formed therethrough sized relative to the port, the insert being retained by the retainer so that the insert aperture and the port are generally aligned; and    a second tubular body having a distal end disposed through the insert aperture and the port for fluid communication with the tubular body central cavity, the second tubular body being formed from a material having a melting temperature greater than that of the insert, wherein the second tubular body is attached to the first tubular body for sealed fluid communication through the port by heating the manifold to a temperature greater than the melting temperature of the insert material and cooling the manifold such that the insert brazes the second tubular body to the first tubular body.    
   
   
       16 . The manifold of  claim 15  wherein a series of ports are formed through the tubular body; 
 wherein the insert further comprises a series of inserts each retained to the tubular body by the retainer and each having an aperture generally aligned with one of the series of ports; and    wherein the second tubular body further comprises a series of tubular bodies, each having a distal end disposed through one of the insert apertures and the corresponding port for fluid communication with the tubular body central cavity.    
   
   
       17 . The manifold of  claim 15  wherein another port is formed through the tubular body, and the manifold further comprises: 
 an insert formed from a material having a melting temperature less than that of the tubular body, the insert having an aperture formed therethrough sized relative to the port, the insert being retained by the retainer so that the insert aperture and the port are generally aligned; and    a fitting having a distal end disposed through the insert aperture and the port for fluid communication with the tubular body central cavity, the fitting being formed from a material having a melting temperature greater than that of the insert, wherein the fitting is attached to the first tubular body for sealed fluid communication through the port by heating the manifold to a temperature greater than the melting temperature of the insert material and cooling the manifold such that the insert brazes the fitting to the first tubular body.    
   
   
       18 . The manifold of  claim 15  further comprising: 
 a bracket sized to be retained by the retainer for fastening the manifold to another component; and    an insert retained by the retainer, the insert being formed from a material having a melting temperature less than that of the tubular body and the bracket, wherein the bracket is attached to the first tubular body by heating the manifold to a temperature greater than the melting temperature of the insert material and cooling the manifold such that the insert brazes the bracket to the first tubular body.    
   
   
       19 . A method for manufacturing a manifold for a heat exchanger comprising: 
 extruding a tubular body with a retainer;    providing a sheet on the tubular body in cooperation with the retainer, the sheet having a melting temperature less than the tubular body;    forming an aperture through the tubular body and the sheet;    inserting a distal end of a second tubular body through the aperture;    heating the manifold to a temperature greater than the melting temperature of the sheet so that the sheet material seeps between the second tubular body and the first tubular body aperture; and    cooling the manifold so that the insert brazes the second tubular body to the first tubular body aperture.    
   
   
       20 . A manifold manufactured by the method of  claim 19.