Tab joint between coolant tube and header

Claim 2

A heat exchanger (10) for exchanging heat with a cooling fluid comprising: first and second fluid tanks (16, 16'); first and second headers (14, 14') fixedly secured to said tanks (16, 16'), respectively, and having a plurality of apertures (22) extending therethrough; each of said apertures (22) including an outwardly extending ferrule (24) disposed circumferentially about said apertures (22); a plurality of fluid coolant tubes (12) having first (28) and second (29) ends connected between said first and second tanks (16, 16') for communicating fluid therebetween; a plurality of joints (26) formed by said ends (28, 29) of said coolant tubes (12) disposed within said apertures (22) of said headers (14, 14'); each of said joints (26) including sealant means (30) for sealing flow of fluid through said joints (26) between said headers (14, 14') and said coolant tubes (12); and each of said joints (26) including at least one tab (32) extending from said ferrule (24) and deformed over said end (28, 29) of said coolant tube (12) to mechanically lock said coolant tube (12) to said header ( 14, 14').

Claim 3

The heat exchanger as set forth in claim 1 further characterized by said apertures (22) having an elliptical periphery defining a major axis (32) and minor axis (34).

Claim 4

The heat exchanger (10) as set forth in claim 2 further characterized by said end (28, 29) of said coolant tubes (12) having an elliptical outer periphery corresponding to said elliptical periphery of said aperture (22).

Claim 5

The heat exchanger (10) as set forth in claim 2 wherein each of said joints said (26) includes a first (56) and second (58) tab and is further characterized by said first tab (56) secured to said ferrule (24) on one side of said major axis (56) and said second tab (58) secured to said ferrule (24) on the opposite side of said major axis (56).

Claim 6

The heat exchanger (10) as set forth in claim 4 further characterized by said first tab (56) secured to said ferrule (24) substantially on one side of said minor axis (54) and said second tab (58) secured to said ferrule (24) on substantially the opposite side of said minor axis (54).

Claim 7

The heat exchanger (10) as set forth in claim 1 further characterized by said joint (26) including solder material (30) disposed between said end (28) of said coolant tube (12) and said header (14).

Claim 8

A heat exchanger (10) for exchanging heat with a cooling fluid comprising: first and second fluid tanks (16, 16'); first and second headers (14, 14') fixedly secured to said tanks (16, 16'), respectively, and having a plurality of apertures (22) extending therethrough; each of said apertures (22) having an elliptical periphery and including an outwardly extending elliptical ferrule (24) disposed circumferentially about said aperture (22); a plurality of fluid coolant tubes (12) having first (28) and second (29) ends connected between said first and second tanks (16, 16') for communicating fluid therebetween; each of said ends (28, 29) of said coolant tubes (12) having an elliptical outer periphery corresponding to said elliptical periphery of said apertures (22); a plurality of joints (26) formed by each of said ends (28, 29) of said coolant tubes (12) disposed within said apertures (22) of said headers (14, 14'); each of said joints (26) including first (56) and second (58) tabs extending from said ferrule (24) and offset along opposite sides of said elliptical periphery of said aperture (22); and each of said tabs (56, 58) deformed over said end (28, 29) of said coolant tube (12) to mechanically lock said coolant tube (12) to said header (14, 14').

Claim 9

A heat exchanger (10) for exchanging heat with a cooling fluid comprising: first and second fluid tanks (16, 16'); first and second headers (14, 14') fixedly secured to said tanks (16, 16'), respectively, and having a plurality of apertures (22) extending therethrough; each of said apertures (22) having an elliptical periphery and including an outwardly extending elliptical ferrule (24) disposed circumferentially about said aperture (22); a plurality of fluid coolant tubes (12) having first (28) and second (29) ends connected between said first and second tanks (16, 16') for communicating fluid therebetween; each of said ends (28, 29) of said coolant tubes (12) having an elliptical outer periphery corresponding to said elliptical periphery of said apertures (22); a plurality of joints (26) formed by each of said ends (28, 29) of said coolant tubes (12) disposed within said apertures (22) of said headers (14, 14'); each of said joints (26) including first (56) and second (58) tabs extending from said ferrule (24) and offset along opposite sides of said elliptical periphery of said aperture (22); and each of said tabs (56, 58) deformed over said end (28, 29) of said coolant tube (12) to mechanically lock said coolant tube (12) to said header (14, 14').

Claim 10

The heat exchanger (10) as set forth in claim 7 further characterized by each of said elliptical apertures (22) defining a major axis (32) and a minor axis (34).

Claim 11

The heat exchanger (10) as set forth in claim 8 further characterized by said first tab (56) secured to said ferule (24) on one side of said major axis (56) and said second tab (58) secured to said ferrule (24) on the opposite side of said major axis (56).

Claim 12

The heat exchanger (10) is set forth in claim 9 further characterized by said first tab (56) secured to said ferrule (24) substantially on one side of said minor axis (54) and said second tab (58) secured to said ferrule (24) on substantially the opposite side of said minor axis (54).

Claim 13

The heat exchanger (10) as set forth in claim 7 further characterized by said joint (26) including solder material (30) disposed between said end (28) of said coolant tube (12) and said header (14) to provide a fluid impervious seal therebetween.