Heat exchanger with clam-shell header

Abstract

A heat exchanger includes a header and a plurality of tubes. The header is configured to contain refrigerant and provide an inlet for the heat exchanger. The plurality of tubes extends away from and is fluidicly coupled to the header. The header includes an upper shell and a lower shell configured to form the header when attached together. The upper shell and the lower shell cooperate to define a manifold portion fluidicly coupled to the inlet, a lanced portion spaced apart from the manifold portion and fluidicly coupled to the plurality of tubes, and a distribution portion configured fluidicly couple the manifold portion to the lanced portion.

We claim: 
     
         1 . A heat exchanger comprising:
 a header configured to contain refrigerant and provide an inlet for the heat exchanger; and   a plurality of tubes extending away from and fluidicly coupled to the header, wherein the header includes   an upper shell and a lower shell configured to form the header when attached together, wherein the upper shell and the lower shell cooperate to define a manifold portion fluidicly coupled to the inlet, a lanced portion spaced apart from the manifold portion and fluidicly coupled to the plurality of tubes, and a distribution portion configured fluidicly couple the manifold portion to the lanced portion.   
     
     
         2 . The heat exchanger in accordance with  claim 1 , wherein the lanced portion is configured to define a plurality of cavities, wherein each cavity is fluidicly coupled to an adjacent cavity only via the manifold portion. 
     
     
         3 . The heat exchanger in accordance with  claim 2 , wherein the distribution portion defines a plurality of distribution passageways that fluidicly couple each cavity to the manifold portion. 
     
     
         4 . The heat exchanger in accordance with  claim 2 , wherein each cavity is configured to receive one of the plurality of tubes such that each tube is fluidicly coupled to an adjacent tube only via the manifold portion. 
     
     
         5 . The heat exchanger in accordance with  claim 1 , wherein the upper shell defines an upper flange and the lower shell defines a lower flange, and the upper flange and the lower flange are brazed together to form the header. 
     
     
         6 . The heat exchanger in accordance with  claim 1 , wherein the header includes a separator located in the manifold portion and configured to segregate the manifold portion into a first region and a second region. 
     
     
         7 . A header for a heat exchanger that includes a plurality of tubes extending away from and fluidicly coupled to the header, said header configured to contain refrigerant and provide an inlet for the heat exchanger, said header comprising:
 an upper shell; and   a lower shell configured to form the header when attached together, wherein the upper shell and the lower shell cooperate to define a manifold portion fluidicly coupled to the inlet, a lanced portion spaced apart from the manifold portion and fluidicly coupled to the plurality of tubes, and a distribution portion configured fluidicly couple the manifold portion to the lanced portion.