Heat exchanger

Abstract

A method of manufacturing a heat exchanger and the heat exchanger made according to the method. The heat exchanger includes a pair of headers that define a plurality of slots. Each of the slots has a pair of nose ends that are disposed within the planar surface. Each of the slots have a first flange and second flange formed on opposite sides of the slots that extend between the pair of nose ends and are recessed into the header relative to the planar surface. One end of each of the tubes is assembled into one of the slots and is connected by a braze weld to the first flange, the second flange, and the nose ends.

What is claimed is: 
     
         1 . A method of making a heat exchanger comprising:
 punching a pair of spaced nose openings in a header;   piercing a portion of the header between the nose openings to form a first flange and a second flange that are recessed into the header and that extend between the pair of nose openings;   attaching a tube to the header; and   brazing the tube to the first flange and the second flange.   
     
     
         2 . The method of  claim 1  further comprising:
 cladding the header with a layer of brazing material before punching and piercing the header. 
 
     
     
         3 . The method of  claim 1  further comprising:
 folding the tube longitudinally to form a plurality of fluid channels in the tube. 
 
     
     
         4 . The method of  claim 3  wherein the tube includes ends that are folded towards a delta region, and further comprising filling the delta region with brazing material. 
     
     
         5 . The method of  claim 3  further comprising cladding the tube before folding the tube. 
     
     
         6 . The method of  claim 1  further comprising brazing the tube to the second flange and the nose openings of the header. 
     
     
         7 . A method of making a heat exchanger comprising:
 cladding a header with a first layer of braze;   punching a pair of spaced nose openings in the header;   piercing a portion of the header between the nose openings to form a first flange and a second flange that are recessed into the header and that extend between the pair of nose openings;   cladding a tube with a second layer of braze;   folding the tube to form a plurality of fluid channels in the tube;   assembling the tube into the header; and   brazing the tube to the first flange, the second flange, and the pair of nose openings on the header.   
     
     
         8 . The method of  claim 7 , wherein the tube includes sides folded towards a delta region, the method further comprising filling the delta region with clad material. 
     
     
         9 . The method of  claim 8 , further comprising brazing the clad material to the first flange. 
     
     
         10 . The method of  claim 8 , wherein the tube includes a belly portion opposite the delta region and further comprising brazing the belly portion to the second flange. 
     
     
         11 . A heat exchanger comprising:
 a plurality of tubes; and   a header having a planar surface and defining a plurality of slots, wherein each of the slots include a pair of nose ends that are disposed within the planar surface, wherein each of the slots have a first flange and second flange formed on opposite sides of the slots that extend between the pair of nose ends and are recessed into the header relative to the planar surface, wherein one end of each of the tubes is assembled into one of the slots and is connected by a braze weld to the first flange, the second flange, and the nose ends.   
     
     
         12 . The heat exchanger of  claim 11 , wherein the tubes are folded longitudinally. 
     
     
         13 . The heat exchanger of  claim 11 , wherein the tubes have sides folded towards a delta region and further comprising a clad material in the delta region. 
     
     
         14 . The heat exchanger of  claim 11 , further comprising a layer of clad material covering the header.