Heat exchanger and method

Abstract

A heat exchanger and a method of manufacturing a heat exchanger for transferring heat energy between first and second working fluids. The heat exchanger can include a housing, a plurality of tubes extending through the housing, and a baffle integrally formed with the housing. The baffle can include one or more fingers that can extend between at least two of the plurality of tubes. The method can include forming a baffle integrally from a side of a housing and positioning the baffle such that it extends into the interior space defined by the housing.

1 . A heat exchanger for transferring heat energy between a first working fluid and a second working fluid, the heat exchanger comprising:
 a housing having a first end and a second end;   a plurality of tubes extending through the housing between the first end and the second end and providing a flow path for the first working fluid; and   a baffle integrally formed with the housing for directing the flow of the second working fluid through the housing.   
   
   
       2 . The heat exchanger of  claim 1 , wherein the baffle includes a finger extending between two of the plurality of tubes. 
   
   
       3 . The heat exchanger of  claim 2 , wherein the finger defines a bypass aperture extending between a first side of the finger and a second side of the finger. 
   
   
       4 . The heat exchanger of  claim 1 , wherein the baffle is moveably supported in the housing for movement relative to at least one of the plurality of tubes. 
   
   
       5 . The heat exchanger of  claim 4 , wherein the baffle is movable in a direction substantially normal to a length of one of the plurality of tubes. 
   
   
       6 . The heat exchanger of  claim 1 , wherein the housing is formed from a first housing portion and a second housing portion secured to the first housing portion, and wherein the baffle extends into an interior space defined between the first housing portion and the second housing portion. 
   
   
       7 . The heat exchanger of  claim 6 , wherein the baffle is a first baffle and is integrally formed with the first housing portion, and further comprising a second baffle extending into the interior space from the second housing portion. 
   
   
       8 . The heat exchanger of  claim 7 , wherein the second baffle is integrally formed with the second housing portion. 
   
   
       9 . The heat exchanger of  claim 6 , wherein the baffle is a first baffle and is integrally formed with the first housing portion, and further comprising a second baffle integrally formed with the first housing portion and extending into the interior space. 
   
   
       10 . The heat exchanger of  claim 1 , wherein the baffle is a first baffle, wherein the first baffle is adjacent to the first end of the housing, and wherein a second baffle is integrally formed with the housing adjacent to the second end of the housing. 
   
   
       11 . A method of manufacturing a heat exchanger for transferring heat energy between a first working fluid and a second working fluid, the method comprising the acts of:
 providing a housing having a first side wall and a second side wall oriented at an angle with respect to the first side wall, together the first and second side walls at least partially defining an interior space;   forming a finger from the first side wall;   positioning a plurality of tubes in the interior space; and   positioning the finger between two of the plurality of tubes.   
   
   
       12 . The method of  claim 11 , wherein forming the finger from the first side wall includes forming a plurality of fingers, and wherein positioning the finger between the two of the plurality of tubes includes moving at least two of the plurality of fingers into the interior space between the plurality of tubes. 
   
   
       13 . The method of  claim 11 , further comprising providing a bypass aperture in the finger such that the working fluid can flow through the finger from an inlet end of the housing toward an outlet end of the housing. 
   
   
       14 . The method of  claim 11 , wherein positioning the finger between the two of the plurality of tubes includes folding the finger into the interior space between the two of the plurality of tubes. 
   
   
       15 . The method of  claim 11 , wherein forming the finger from the first side wall includes cutting the first side wall. 
   
   
       16 . The method of  claim 11 , further comprising moving the finger relative to the first side wall in a direction substantially normal to a longitudinal axis of one of the plurality of tubes. 
   
   
       17 . The method of  claim 11 , wherein forming the finger from the first side wall includes molding the first finger. 
   
   
       18 . A method of manufacturing a heat exchanger for transferring heat energy between a first working fluid and a second working fluid, the method comprising the acts of:
 providing a generally planar housing plate;   folding the plate to define a first side wall and a second side wall oriented at an angle with respect to the first side wall such that the first and second side walls together at least partially define an interior space;   positioning a plurality of tubes in the internal space;   forming a baffle from the first side wall; and   folding the baffle with respect to the first side wall and into engagement with at least one of the plurality of tubes.   
   
   
       19 . The method of  claim 18 , wherein forming the baffle from the first side wall includes cutting the first side wall. 
   
   
       20 . The method of  claim 18 , further comprising piercing the baffle to provide a bypass channel through the baffle connecting an inlet side of the housing with an outlet side of the housing. 
   
   
       21 . The method of  claim 18 , further comprising providing an elastic element between the baffle and the first side wall, the elastic element being deformable to allow movement of the baffle in a direction substantially normal to a flow path of the first working fluid through the housing. 
   
   
       22 . The method of  claim 18 , further comprising moving the baffle relative to the first side wall in a direction substantially normal to a longitudinal axis of one of the plurality of tubes. 
   
   
       23 . The method of  claim 18 , wherein forming the baffle from the first side wall includes forming a finger extending outwardly from the baffle, and wherein folding the baffle with respect to the first side wall and into engagement with the at least one of the plurality of tubes includes positioning the finger between two of the plurality of tubes.