Condenser header and tank assembly with interference fit baffle

Claim 2

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate being flat and having an outer abutment edge which abuts and deforms the interior walls of the header portion and tank portion in an interference fit when the header portion and tank portion are joined together, the deformation of the interior walls of the header portion and tank portion enhancing sealing of the abutment edge to the interior walls.

Claim 3

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein at least one of the header portions and tank portions has a plate slot extending therethrough, and wherein at least one of the plates has a tab extending past its abutment edge for entering the plate slot.

Claim 4

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein at least one of the header portions and tank portions has a plate slot extending therethrough, and wherein at least one of the plates has a tab extending past its abutment edge for entering the plate slot.

Claim 5

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein the abutment edge of the plate circumscribes an area that is greater than the flow area of the header and tank assembly.

Claim 6

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein the abutment edge of the plate circumscribes an area that is greater than the flow area of the header and tank assembly.

Claim 7

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein each of the header and tank portions has a plate slot positioned to align with each other when the header and tank portions are joined together, and wherein at least one of the plates has a plurality of tabs extending past its abutment edge for entering the plate slots.

Claim 8

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein each of the header and tank portions has a plate slot positioned to align with each other when the header and tank portions are joined together, and wherein at least one of the plates has a plurality of tabs extending past its abutment edge for entering the plate slots.

Claim 9

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein the flow area is generally oval shaped.

Claim 10

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together with interior walls of the header portion and tank portion defining a flow area, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the improvement comprising in combination: at least one flow blocking plate located in at least one of the header and tank assemblies, each plate having an outer abutment edge which abuts the interior walls of the header portion and tank portion in an interference fit, causing deformation of the interior walls of the header portion and tank portion to enhance sealing of the abutment edge to the interior walls; and wherein the flow area is generally oval shaped.

Claim 11

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together, with interior walls of the header and tank assembly and tank portion defining a conduit for refrigerant flow, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the header portion and the tank portion each having at least one plate slot, the plate slots axially aligning with each other when the header portion and tank portion are joined together, the improvement comprising in combination: at least one plate located in at least one of the header and tank assemblies for blocking refrigerant flow, each plate having a plurality of tabs, each of which inserts into one of the plate slots, each plate having abutment edges at its perimeter extending between the tabs which abut the interior walls of the header and tank portions in an interference fit, causing deformation of the interior walls of the header and tank portions to enhance sealing of the abutment edges to the interior walls.

Claim 12

In a heat exchanger having a plurality of parallel tubes extending between a pair of header and tank assemblies, each header and tank assembly having a header portion and a tank portion which are joined together, with interior walls of the header and tank assembly and tank portion defining a conduit for refrigerant flow, the header portion having a plurality of tube slots for receiving ends of the tubes to flow refrigerant between the header and tank assemblies and the tubes, the header portion and the tank portion each having at least one plate slot, the plate slots axially aligning with each other when the header portion and tank portion are joined together, the improvement comprising in combination: at least one plate located in at least one of the header and tank assemblies for blocking refrigerant flow, each plate having a plurality of tabs, each of which inserts into one of the plate slots, each plate having abutment edges at its perimeter extending between the tabs which abut the interior walls of the header and tank portions in an interference fit, causing deformation of the interior walls of the header and tank portions to enhance sealing of the abutment edges to the interior walls.

Claim 13

The heat exchanger according to claim 6 wherein the dimensions across the plate from one side of the abutment edge to an opposite side are greater by an amount in the range from 0.01 mm to 0.5 mm than the corresponding dimensions across the interior walls.

Claim 14

The heat exchanger according to claim 6 wherein the header and tank assembly is generally oval in configuration.

Claim 15

In a method of assembling a heat exchanger header and tank assembly, which includes providing a tank portion and a header portion which have interior walls when assembled together define a flow area, and forming tube slots in the header portion, the improvement comprising: providing at least one baffle plate having an abutment edge which circumscribes an area that is larger than the flow area of the header and tank assembly; inserting the plate into one of the portions; then assembling the tank portion and header portion in engagement with each other with the plate located therein, and pressing the portions together with sufficient force to cause the abutment edge of the plate to deform the interior walls slightly to enhance sealing between the plate and the interior walls.

Claim 16

In a method of assembling a heat exchanger header and tank assembly, which includes providing a tank portion and a header portion which have interior walls when assembled together define a flow area, and forming tube slots in the header portion, the improvement comprising: providing at least one baffle plate having an abutment edge which circumscribes an area that is larger than the flow area of the header and tank assembly; inserting the plate into one of the portions; then assembling the tank portion and header portion in engagement with each other with the plate located therein, and pressing the portions together with sufficient force to cause the abutment edge of the plate to deform the interior walls slightly to enhance sealing between the plate and the interior walls.

Claim 17

The method according to claim 9 wherein the method further comprises: providing at least one of the portions with a plate slot; and providing at least one of the plates with a tab extending past its abutment edge; then inserting the tab into the plate slot while inserting the plate into one of the portions.

Claim 18

The heat exchanger according to claim 9 wherein the method further comprises: providing each of the portions with a plate slot; providing the plate with a plurality of tabs extending past its abutment edge for entering the plate slots; then inserting the tabs into the plate slots while inserting the plate into one of the portions and while assembling the portions together.

Claim 19

In a method of assembling a heat exchanger, which includes providing a tank portion and a header portion which have interior walls when assembled together define a flow area, and forming tube slots in the header portion, the improvement comprising: providing each of the portions with a plate slot; providing at least one baffle plate having an abutment edge which circumscribes an area that is larger than the flow area of the header and tank assembly; providing the plate with a plurality of tabs extending past its abutment edge for entering the plate slots; then inserting the plate into one of the portions, with one of the tabs locating within one of the plate slots; then assembling the tank portion and header portion in engagement with each other with the plate located therein, and locating another of the tabs in the other of the plate slots; pressing the assembled portions together with sufficient force to cause the abutment edge of the plate to deform the interior walls slightly to enhance sealing between the plate and the interior walls; then clamping the assembled portions together; then inserting tubes into the tube slots.

Claim 20

In a method of assembling a heat exchanger, which includes providing a tank portion and a header portion which have interior walls when assembled together define a flow area, and forming tube slots in the header portion, the improvement comprising: providing each of the portions with a plate slot; providing at least one baffle plate having an abutment edge which circumscribes an area that is larger than the flow area of the header and tank assembly; providing the plate with a plurality of tabs extending past its abutment edge for entering the plate slots; then inserting the plate into one of the portions, with one of the tabs locating within one of the plate slots; then assembling the tank portion and header portion in engagement with each other with the plate located therein, and locating another of the tabs in the other of the plate slots; pressing the assembled portions together with sufficient force to cause the abutment edge of the plate to deform the interior walls slightly to enhance sealing between the plate and the interior walls; then clamping the assembled portions together; then inserting tubes into the tube slots.