Impact resistant structural radiator tube

Abstract

An impact-resistant heat exchanger for a vehicle is provided with a region that does not transfer fluid but instead resists impacts from foreign objects, such as stones or debris. The heat exchanger includes first and second header tanks configured to contain a fluid to flow through the heat exchanger, as well as a tube extending between the header tanks. The tube has a fluid-transferring region fluidly coupling the first and second header tanks that is configured to transfer fluid between the first and second header tanks. The tube also has an impact-resistant region fluidly isolated from the fluid-transferring region and not fluidly coupling the first and second header tanks. The impact-resistant region has a rear edge adjacent the fluid-transferring region and an opposing leading edge.

What is claimed is: 
     
         1 . An impact-resistant heat exchanger for a vehicle, the heat exchanger comprising:
 first and second header tanks configured to contain a fluid to flow through the heat exchanger; and   a tube extending between the first and second header tanks, the tube having
 a fluid-transferring region fluidly coupling the first and second header tanks and configured to transfer fluid between the first and second header tanks, and 
 an impact-resistant region fluidly isolated from the fluid-transferring region and not fluidly coupling the first and second header tanks, the impact-resistant region having a rear edge adjacent the fluid-transferring region and an opposing leading edge; 
   wherein the impact-resistant region defines a pair of scalloped corners connecting the leading edge to the fluid-transferring region.   
     
     
         2 . The heat exchanger of  claim 1 , wherein the first header tank includes a first leading edge forwardly aligned with the leading edge of the impact-resistant region, and the second header tank includes a second leading edge forwardly aligned with the leading edge of the impact-resistant region. 
     
     
         3 . The heat exchanger of  claim 1 , wherein the scalloped corners are concave relative to the impact-resistant region. 
     
     
         4 . The heat exchanger of  claim 1 , wherein the scalloped corners include a first scalloped corner adjacent to but spaced from the first header tank, and a second scalloped corner adjacent to but spaced from the second header tank. 
     
     
         5 . The heat exchanger of  claim 1 , wherein the scalloped corners do not contact either of the first or second header tanks. 
     
     
         6 . The heat exchanger of  claim 1 , wherein the impact-resistant region includes a plurality of impact-resistant structures between the rear edge and the leading edge. 
     
     
         7 . The heat exchanger of  claim 6 , wherein the impact-resistant structures include a plurality of undulations formed therein. 
     
     
         8 . The heat exchanger of  claim 6 , wherein the impact-resistant region is defined by a single bent sheet of material that also defines the impact-resistant structures. 
     
     
         9 . An impact-resistant heat exchanger for a vehicle, the heat exchanger comprising:
 an inlet header tank defining an inlet configured to receive fluid into the heat exchanger, the inlet header tank having a first plurality of vertically-stacked openings;   an outlet header tank defining an outlet configured to dispense the fluid from the heat exchanger, the outlet header tank having a second plurality of vertically-stacked openings; and   a plurality of tubes extending between the inlet header tank and the outlet header tank, each tube defining:   a fluid-transferring region extending between first and second ends thereof, the first end engaging with one of the first plurality of openings, and the second end engaging with one of the second plurality of openings to fluidly couple the inlet header tank to the outlet header tank, and   an impact-resistant region fluidly isolated from the fluid-transferring region, wherein the impact-resistant region is not engaged with any of the first or second plurality of openings.   
     
     
         10 . The heat exchanger of  claim 9 , wherein the fluid-transferring region and the impact-resistant region of each tube are formed as a single integral unit. 
     
     
         11 . The heat exchanger of  claim 10 , wherein the fluid-transferring region and the impact-resistant region of each tube is formed from a single sheet of material. 
     
     
         12 . The heat exchanger of  claim 9 , further comprising a plurality of fins extending between the inlet header tank and the outlet header tank and between two adjacent tubes, wherein the impact-resistant region extends forward relative to the fins. 
     
     
         13 . The heat exchanger of  claim 9 , wherein the impact-resistant region of each tube does not contact either of the inlet header tank or the outlet header tank. 
     
     
         14 . The heat exchanger of  claim 13 , wherein each impact-resistant region includes a leading edge, a rear edge, a first scalloped corner connecting the leading edge to the rear edge, and a second scalloped corner connecting the leading edge to the rear edge. 
     
     
         15 . The heat exchanger of  claim 14 , wherein the first scalloped corner is adjacent to but spaced from the inlet header tank defining a first gap therebetween, and the second scalloped corner is adjacent to but spaced from the outlet header tank defining a second gap therebetween. 
     
     
         16 . An impact-resistant heat exchanger for a vehicle, the heat exchanger comprising:
 first and second header tanks configured to contain a fluid to flow through the heat exchanger; and   a tube extending between the first and second header tanks, the tube having
 a fluid-transferring region fluidly coupling the first and second header tanks and configured to transfer fluid between the first and second header tanks, and 
 an impact-resistant region fluidly isolated from the fluid-transferring region and configured to not transfer fluid between the first and second header tanks, the impact-resistant region having a rear edge adjacent the fluid-transferring region and an opposing leading edge; 
   wherein the impact-resistant region defines a plurality of impact-resistant structures between the rear edge and the leading edge.   
     
     
         17 . The heat exchanger of  claim 16 , wherein the impact-resistant structures define a plurality of stacked undulations. 
     
     
         18 . The heat exchanger of  claim 17 , wherein the plurality of stacked undulations collectively extend from the rear edge and partially toward the leading edge. 
     
     
         19 . The heat exchanger of  claim 17 , wherein each undulation individually extends widthwise across the impact-resistant region. 
     
     
         20 . The heat exchanger of  claim 16 , wherein the impact-resistant region includes an upper surface and a lower surface, and the impact-resistant structures are contained within the upper surface and the lower surface.