Heat exchanger and method of manufacturing the same

Abstract

The present invention provides, among other things, a heat exchanger including a plurality of tubes providing a flow path for a first fluid, a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid. Together, the fin and the plurality of tubes at least partially define a heat exchanger core. The heat exchanger can also include first and second tanks positioned adjacent to opposite ends of the plurality of tubes and an elastically deformable side part extending across the heat exchanger core and including a pair of integrally formed caps for closing openings in the first and second tanks.

1 . A heat exchanger comprising:
 a plurality of tubes providing a flow path for a first fluid;   a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid, together, the fin and the plurality of tubes at least partially defining a core;   first and second tanks positioned adjacent to opposite ends of the plurality of tubes; and   an elastically deformable side part extending across the heat exchanger core and including a pair of integrally formed caps for closing openings in the first and second tanks.   
   
   
       2 . The heat exchanger of  claim 1 , wherein one of the pair of caps contacts the heat exchanger core. 
   
   
       3 . The heat exchanger of  claim 1 , wherein the side part includes a rigid central part arranged between the caps and contacting an outermost tube of the heat exchanger core. 
   
   
       4 . The heat exchanger of  claim 1 , wherein the side part is elastically deformable in a direction generally parallel to a length between the opposite ends of one of the plurality of tubes. 
   
   
       5 . The heat exchanger of  claim 1 , wherein the side part includes at least one elastic region having an elliptically-shaped expansion gap, and wherein webs extend across the gap between the caps and a central part of the side part. 
   
   
       6 . The heat exchanger of  claim 1 , wherein the side part includes at least one elastic region having an expansion web extending between a central part and one of the pair of caps. 
   
   
       7 . The heat exchanger of  claim 1 , wherein the first tank includes outwardly extending protrusions engageable in one of the ends of the plurality of tubes. 
   
   
       8 . The heat exchanger of  claim 1 , wherein the side part includes an expansion gap, and wherein a connector extends outwardly from the side part through the expansion gap for engaging the first tank. 
   
   
       9 . A heat exchanger comprising:
 a plurality of tubes providing a flow path for a first fluid, the plurality of tubes having narrow sides and broad sides;   a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid; and   a tank positioned adjacent to ends of the plurality of tubes and including first and second tank members joined together along a connection plane, the tank having outwardly-extending projections engageable in the ends of the tubes adjacent to the narrow sides to secure the tank to the tubes.   
   
   
       10 . The heat exchanger of  claim 9 , wherein the ends of the tubes are received in openings in headers positioned adjacent to the first tank, and wherein portions of the tubes protrude outwardly beyond side edges of the headers, the side edges being transverse to the ends of the tubes. 
   
   
       11 . The heat exchanger of  claim 10 , wherein the projections are received in the protruding portions of the ends of the tubes and engage interior sides of the narrow sides of the tubes. 
   
   
       12 . The heat exchanger of  claim 9 , wherein the first and second members at least partially define an interior space, and wherein a portion of an outer wall of the first member extends inwardly through the interior space engaging a portion of an outer wall of the second member. 
   
   
       13 . The heat exchanger of  claim 9 , wherein the projections extend outwardly from each of the first and second members, and wherein projections from the first member and projections from the second member are engageable in the ends of the tubes adjacent to the narrow sides. 
   
   
       14 . The heat exchanger of  claim 9 , further comprising a partitioning wall extending through an interior of the tank in a direction substantially parallel to a longitudinal extent of the projections to at least partially define the flow path of the first fluid through the tank. 
   
   
       15 . The heat exchanger of  claim 14 , wherein the partitioning wall includes projections engageable in the ends of the plurality of tubes. 
   
   
       16 . The heat exchanger of  claim 14 , wherein the ends of the tubes are received in openings in a header, and wherein the partitioning wall is engageable in a slit formed in the header. 
   
   
       17 . A heat exchanger comprising:
 a plurality of tubes providing a flow path for a first fluid;   a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid, together, the fin and the plurality of tubes at least partially defining a core;   first and second tanks positioned adjacent to opposite ends of the plurality of tubes; and   a side part extending across the core between the first and second tanks and including outwardly extending projections engageable in the ends of the tubes.   
   
   
       18 . The heat exchanger of  claim 17 , wherein the side part includes a first member secured to a second member, the first member being adjacent to the first tank and including projections engageable with first ends of the tubes and the second member being adjacent to the second tank and including projections engageable with second ends of the tubes. 
   
   
       19 . The heat exchanger of  claim 18 , wherein one of the first member and the second member defines a recess and an other of the first member and the second member includes a protrusion moveable through the recess a distance to connect the first member to the second member during movement of the first member with respect to the second member, and wherein the distance corresponds to a length of the projections. 
   
   
       20 . The heat exchanger of  claim 18 , wherein the first member is connected to the second member along a seam, and wherein the seam directs the second fluid along a substantially serpentine path through the heat exchanger. 
   
   
       21 . The heat exchanger of  claim 17 , wherein the first tank includes openings for receiving the ends of the tubes, and wherein sides of the tubes extend outwardly beyond outer edges of the first tank. 
   
   
       22 . The heat exchanger of  claim 17 , wherein the portions of the ends of the tubes engaged with the projections extend outwardly beyond outer edges of the first tank. 
   
   
       23 . The heat exchanger of  claim 17 , wherein the side part is a first side part, further comprising a second side part extending across the heat exchanger core between the first and second tanks and including outwardly extending projections engageable in the ends of the tubes, and wherein the first and second side parts at least partially enclose the heat exchanger core. 
   
   
       24 . A heat exchanger comprising:
 a plurality of tubes providing a flow path for a first fluid;   a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid; and   a tank secured to and in fluid communication with the ends of the plurality of tubes and including first and second tank members at least partially defining an interior space, a portion of an outer wall of the first tank member extending inwardly through the interior space and engaging a portion of an outer wall of the second tank member.   
   
   
       25 . The heat exchanger of  claim 24 , wherein the first tank member and the second tank member are stamped parts. 
   
   
       26 . The heat exchanger of  claim 24 , wherein the portion of the outer wall of the first tank member directs the flow of the first fluid through the interior space and distributes the first fluid among the tubes. 
   
   
       27 . The heat exchanger of  claim 24 , wherein the portion of the outer wall of the first tank member has a substantially convex shape. 
   
   
       28 . The heat exchanger of  claim 27 , wherein the tank includes in an inlet for receiving the first fluid, the inlet being oriented to direct the first fluid onto the convex portion of the outer wall of the first tank member to distribute the first fluid through the interior space. 
   
   
       29 . A method of assembling a heat exchanger, the method comprising the acts of:
 stamping a first tank member and depressing a portion of an outer wall of the first tank member;   stamping a second tank member and depressing a portion of an outer wall of the second tank member;   connecting the first tank member to the second tank member such that the depressed portion of the first tank member extends through an interior space at least partially enclosed by the first and second tank members toward the depressed portion of the second tank member to direct a first fluid through the interior space; and   connecting a heat exchanger core to the first and second tank members, the heat exchanger core including a plurality of tubes providing a flow path for the first fluid and a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid.   
   
   
       30 . The method of  claim 29 , wherein connecting the first tank member to the second tank member includes securing the depressed portion of the first tank member to the depressed portion of the second tank member. 
   
   
       31 . The method of  claim 29 , wherein depressing the portion of the outer wall of the first tank member includes forming a first convex protrusion, and wherein depressing the portion of the outer wall of the second tank member includes forming a second convex protrusion.