Manifold with multiple passages and cross-counterflow heat exchanger incorporating the same

Abstract

A manifold having multiple chambers for use in a cross-counterflow heat exchanger assembly includes a first member having arms extending from a base to arm ends. A second member is secured to the first member to define the manifold. The second member includes an inner plate edge that defines a first mating surface that extends inwardly along the inner plate edge from each of the plate ends to mate with arm ends. A wall extends transversely to the inner plate edge to a wall end. The wall end mates with an inner base surface to divide the interior of the manifold into a plurality of chambers. At least one lip extends transversely to the inner plate edge to define a second mating surface that extends perpendicularly from the first mating surface and mates with an inner arm surface of the arms.

1 . A manifold for use in a heat exchanger assembly comprising:
 a first member presenting arms integrally connected to a base having an inner base surface, each of said arms having an inner arm surface and extending from said base to an arm end;   a second member secured to said first member to define said manifold, said second member having a plate extending between plate ends and between an inner plate edge and an outer plate edge, and said inner plate edge defining a first mating surface extending inwardly along said inner plate edge from each of said plate ends to mate with arm ends;   a wall extending transversely to said inner plate edge of said plate to a wall end, said wall end mating with said inner base surface to divide the interior of said manifold into a plurality of chambers; and   at least one lip extending transversely to said inner plate edge of said second member to define a second mating surface that extends perpendicularly from said first mating surface and mates with said inner arm surface of said arms.   
   
   
       2 . The manifold as set forth in  claim 1  wherein each of said arms includes a stress therein to cant said arm ends toward one another and wherein said canted arms create a clamping force on said second mating surface of said lip for temporally securing said second member to said first member. 
   
   
       3 . The manifold as set forth in  claim 1  wherein said base defines a plurality of longitudinally spaced first tube slots and at least one opening disposed between adjacent ones of said first tube slots. 
   
   
       4 . The manifold as set forth in  claim 3  wherein said wall end is contoured to conform with said inner base surface for positioning said wall end against said inner base surface and said first tube slots. 
   
   
       5 . The manifold as set forth in  claim 4  wherein said wall end of the second member defines a plurality of notches being spaced to correspond with said first tube slots of said first member. 
   
   
       6 . The manifold as set forth in  claim 3  wherein said wall includes at least one locking arm extending from said wall end to mate with said at least one opening to secure said second member to said first member. 
   
   
       7 . The manifold as set forth in  claim 1  wherein said manifold extends longitudinally between first and second manifold ends. 
   
   
       8 . The manifold as set forth in  claim 7  including a cap disposed at each of said first and second manifold ends. 
   
   
       9 . The manifold as set forth in  claim 1  further including an input in communication with an input chamber for receiving a fluid and an output in communication with an output chamber for dispensing the fluid. 
   
   
       10 . The manifold as set forth in  claim 1  wherein said second member defines a longitudinally extending groove between said first and second mating surfaces for accommodating a burr between said first and second members. 
   
   
       11 . A cross-counterflow heat exchanger assembly comprising:
 a first member presenting arms integrally connected to a base having an inner base surface, each of said arms having an inner arm surface and extending from said base to an arm end, said base defining a plurality of longitudinally spaced first tube slots;   a second member secured to said first member to define a manifold, said second member having a plate extending between plate ends and between an inner plate edge and an outer plate edge, and said inner plate edge defining a first mating surface extending inwardly along said inner plate edge from each of said plate ends to mate with arm ends;   a wall extending transversely to said inner plate edge of said plate to a wall end, said wall end mating with said inner base surface to divide the interior of said manifold into a plurality of chambers;   at least one lip extending transversely to said inner plate edge of said second member to define a second mating surface that extends perpendicularly from said first mating surface and mates with said inner arm surface of said arms;   a return manifold extending in spaced and parallel relationship with said manifold and defining a plurality of longitudinally spaced second tube slots to correspond with said first tube slots of said manifold;   a plurality of tubes extending between first and second tube ends, each of said first tube ends engaging each of said first tube slots and each of said second tube ends engaging each of said second tube slots to establish fluid communication between said manifold and said return manifold, and wherein adjacent tubes are spaced from one another to define a plurality of air passages for the flow of air between said adjacent tubes; and   an air fin disposed between and brazed to said tubes and extending between said manifold and said return manifold for dissipating heat from said tubes.   
   
   
       12 . The assembly as set forth in  claim 11  wherein each of said tubes define a tube divider extending between said first and second tube ends to define a first passage in fluid communication with one of said chambers of said manifold and a second passage in fluid communication with the other of said chambers of said manifold. 
   
   
       13 . The assembly as set forth in  claim 11  wherein said wall end of the second member defines a plurality of notches being spaced to correspond with said first tube slots of said first member and wherein said tube divider at said first tube end abuts said notches of said wall end of said second member. 
   
   
       14 . The assembly as set forth in  claim 11  wherein each of said tubes has a cross-section defining parallel flat sides extending between round ends. 
   
   
       15 . 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;   temporarily fixing the first member to the second member to define a manifold extending between first and second manifold ends after the separately forming step; and   permanently fixing the first member to the second member.   
   
   
       16 . The method as set forth in  claim 15  wherein the temporarily fixing step is further defined as canting arms of the first member inwardly to create a stress therein and on a second mating surface defined by a lip on said second member. 
   
   
       17 . The method as set forth in  claim 15  further including the step of:
 placing a cap on the first and second manifold ends prior to the permanently fixing step.   
   
   
       18 . The method as set forth in  claim 15  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.