Heat exchanger construction

Abstract

An improved heat exchanger is disclosed. The heat exchanger is of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers. The improvement comprises a tubular structure for and defining in part each of said headers. The tubular structure is defined by a pair of body elements and has opposed longitudinal joints defined by overlapping portions of the body elements. One of the body elements overlaps the other of the body elements to define one of the joints and is overlapped by the other of the body elements to define the other of the joints.

1 . An improved heat exchanger, said heat exchanger being of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers, the improvement comprising:
 a tubular structure for and defining in part each of said headers, the tubular structure being defined by a pair of body elements and having opposed longitudinal joints defined by overlapping portions of the body elements,   wherein one of the body elements overlaps the other of the body elements to define one of the joints and is overlapped by the other of the body elements to define the other of the joints.   
   
   
       2 . An improved heat exchanger according to  claim 1 , characterized in that: the one of the body elements has an aperture for each tube; and each tube interfaces with the other of the body elements in a single butt joint. 
   
   
       3 . An improved heat exchanger according to  claim 1 , wherein
 the body elements are channels of arcuate profile with longitudinal edge portions that define the overlapping portions; and   measured in the direction by which the longitudinal edge portions of the other of the body elements are spaced-apart from one another, an outer width of each tube is substantially equal to the distance by which said longitudinal edge portions are spaced-apart.   
   
   
       4 . A heat exchanger selected from the group including condensers and evaporators for automotive air conditioners and automotive oil coolers and radiators, the heat exchanger being of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers, the improvement comprising:
 a cover and a pan interfitted with and brazed to the cover to define each tube.   
   
   
       5 . An improved heat exchanger according to  claim 4 , wherein:
 a tubular structure is provided for and defines in part each of said pair of headers; and   the tubes are brazed to the headers.   
   
   
       6 . An improved heat exchanger according to  claim 5 , wherein the tubular structure is defined by a pair of body elements of arcuate profile brazed together. 
   
   
       7 . An improved heat exchanger according to  claim 4 , characterized in that in each tube a turbulizer is provided, the turbulizer including a pair of coplanar base flanges dimensioned to centre the turbulizer in the tube. 
   
   
       8 . An improved turbulizer of the type for use in a tube formed of cooperating portions brazed together, the improvement comprising:
 a pair of coplanar flanges dimensioned to centre the turbulizer in the tube in use.   
   
   
       9 . A method for constructing a heat exchanger, the heat exchanger being of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers, the method comprising the steps of:
 for each header, providing a pair of body elements each formed of brazing clad material; and   brazing the body elements together such that the headers each have opposed longitudinal joints defined by overlapping portions of the body elements, one of the body elements overlapping the other of the body elements to define one of the joints and being overlapped by the other of the body elements to define the other of the joints.   
   
   
       10 . A method according to  claim 9 , wherein
 for each tube, a tubular assembly formed of brazing clad material is provided; and   one of the body elements has an aperture formed therein for each tube and the tubular assembly for each tube is fitted into the apertures formed for said each tube; and   the body elements and the tubular assemblies are brazed together to form said heat exchanger.   
   
   
       11 . A method according to  claim 10 , wherein each tubular assembly interfaces with the other of the body elements in a single butt joint. 
   
   
       12 . A method according to  claim 10 , wherein
 the body elements are channels of arcuate profile with longitudinal edge portions that define the overlapping portions; and   in the heat exchanger, measured in the direction by which the longitudinal edge portions of the other of the body elements are spaced-apart from one another, an outer width of each tube is substantially equal to the distance by which said longitudinal edge portions are spaced-apart.   
   
   
       13 . A method of constructing a heat exchanger selected from the group including condensers and evaporators for automotive air conditioners and automotive oil coolers and radiators, said heat exchanger being of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers, the method comprising the steps of:
 for each header, providing a tubular structure formed of brazing clad material, the tubular structure having an aperture formed therein for each tube;   for each tube, providing a cover and a pan, both formed of brazing clad material; and fitting the pan into the cover to form a tubular assembly;   fitting the tubular assembly for each tube into the apertures formed for said each tube; and   brazing the tubular structures, the covers and the pans together.   
   
   
       14 . A method according to  claim 13 , wherein:
 for each tubular structure is provided a pair of body elements each formed of brazing clad material, one of the body elements defining the apertures for said each tubular structure; and   the body elements are fitted together to form said tubular structure, and brazed to one another when the tubular structures, the covers and the pans are brazed together.   
   
   
       15 . A method according to  claim 13 , wherein, for each tube, a turbulizer is provided and fitted into the cover provided for said each tube to form a tube subassembly, into which tube subassembly the pan provided for said each tube is fitted to form the tubular assembly. 
   
   
       16 . A method according to  claim 15 , wherein each turbulizer is provided with a pair of coplanar flanges dimensioned to centre said each turbulizer in the tube for which it is provided. 
   
   
       17 . A method according to  claim 16 , wherein: each of the pan and cover includes a body plate and a pair of peripheral flanges extending from the body plate; and prior to assembly of the pan and cover, the turbulizer is inserted into the cover, with the flanges seated against the cover body plate. 
   
   
       18 . An improved heat exchanger, the heat exchanger being of the type including a pair of headers and a plurality of tubes extending between and fluidly connecting the headers, the improvement comprising:
 a cover and a pan interfitted with and brazed to the cover to define each tube,   wherein, in each tube a turbulizer is provided, the turbulizer including a pair of coplanar base flanges dimensioned to centre the turbulizer in the tube.   
   
   
       19 . An improved heat exchanger according to  claim 18 , wherein
 a tubular structure is provided for and defines in part each of said pair of headers, the tubular structure being defined by a pair of body elements brazed together.