Cross-counterflow heat exchanger assembly

Abstract

A manifold for use in a heat exchanger assembly and a method of forming the manifold is disclosed herein. The method starts with the step of separately forming a first member at least partially defining an interior and having a spaced set of first tube slots and a second member having a wall positioned against the first tube slots and dividing the interior into a plurality of chambers. The method is finalized with the step of permanently fixing the first member to the second member to define an first manifold after the separately forming step.

1 . A method of forming a manifold for use in a heat exchanger assembly including the steps of:
 separately forming a first member at least partially defining an interior and having a spaced set of first tube slots and a second member having a wall positioned against the first tube slots and dividing the interior into a plurality of chambers; and   permanently fixing the first member to the second member to define an first manifold after the separately forming step.   
     
     
         2 . The method as set forth in  claim 1  wherein the forming the first member is further defined as rolling a flat sheet of material into a channel having a cross-section presenting a U-shape presenting a base and arms extending forwardly to arm ends. 
     
     
         3 . The method as set forth in  claim 1  further including the step of:
 forming a plurality of tubes extending between first and second tube ends.   
     
     
         4 . The method as set forth in  claim 3  wherein the forming each tube is further defined by rolling a flat sheet of material into a tube defining a tube divider. 
     
     
         5 . The method as set forth in  claim 3  further including the step of:
 forming a tube divider extending between the first and second tube ends in each of the tubes to separate each tube into a first passage and a second passage.   
     
     
         6 . The method as set forth in  claim 5  further including the step of:
 inserting the first tube end of each tube into one of the first tube slots of the first manifold and abutting the tube divider of each tube against the wall to establish fluid communication between the first passage of the tubes and one of the chambers of the first manifold and to establish fluid communication between the second passage of the tubes and the other of the chambers of the first manifold.   
     
     
         7 . The method as set forth in  claim 6  further including the step of:
 forming a second manifold having a set of spaced second tube slots to correspond with the set up first tube slots of the first manifold.   
     
     
         8 . The method as set forth in  claim 7  further including the step of:
 inserting the second tube end of each of the tubes into the corresponding second tube slot of the second manifold to establish fluid communication between the first and second passages of each tube and the second manifold.   
     
     
         9 . The method as set forth in  claim 8  further including the step of:
 forming a plurality of air fins.   
     
     
         10 . The method as set forth in  claim 9  further including the step of:
 inserting an air fin between adjacent tubes to dissipate heat from the tubes.   
     
     
         11 . An assembly manufactured according to the method of  claim 1 . 
     
     
         12 . The assembly as set forth in  claim 11  wherein said first member extends longitudinally and said first tube slots are longitudinally spaced from each other. 
     
     
         13 . The assembly as set forth in  claim 11  wherein said first member is a channel having a cross-section defining a U-shape and presenting arms integrally connected to a base and extending forwardly to arm ends. 
     
     
         14 . The assembly as set forth in  claim 13  wherein said second member includes a plate extending between said arm ends of said channel and said wall extends transversely from said plate to said tube slots of said channel. 
     
     
         15 . The assembly as set forth in  claim 11  further comprising:
 an input disposed on one of said chambers to receive a fluid and to define an input chamber and an output disposed on the other of said chambers to dispense the fluid and to define an output chamber.   
     
     
         16 . The assembly as set forth in  claim 11  further comprising:
 a plurality of tubes extending between first and second tube ends; and   said first tube end of each of said tubes is disposed in one of said first tube slots of said first manifold.   
     
     
         17 . The assembly as set forth in  claim 16  wherein each of said defines a tube divider extending between said first and second tube to define a first passage in fluid communication with one of said chambers of said first manifold and a second passage in fluid communication with the other of said chambers; and
 said tube divider at said first tube end abuts said wall of said second member.   
     
     
         18 . The assembly as set forth in  claim 17  further comprising:
 a second manifold extending in spaced and parallel relationship with said first manifold and end engaging said second tube ends of said plurality of tubes to establish fluid communication between said first and second passages of said tubes and said second manifold.   
     
     
         19 . The assembly as set forth in  claim 18  wherein said second manifold defines a plurality of second tube slots spaced from each other to correspond with said first tube slots of said first manifold, and
 said second end of each of said tubes extends into said corresponding second tube slot.   
     
     
         20 . The assembly as set forth in  claim 19  wherein each of said tubes has a cross-section defining flat sides and round ends. 
     
     
         21 . The assembly as set forth in  claim 20  wherein said flat sides of adjacent tubes are spaced from one another to define a plurality of air passages for the flow of air between said adjacent tubes. 
     
     
         22 . The assembly as set forth in  claim 21  further comprising:
 an air fin disposed between and brazed to said parallel flat sides of said tubes and extending between said first and second manifolds for dissipating heat from said tubes.