The present invention relates to a heat exchanger, more particularly, the present invention relates to a header-tank assembly for the heat exchanger.

Referring to FIG. 1a - FIG. 1c of the accompanying drawings, a prior art heat exchanger such as for example a heat exchanger 01 used in a vehicle includes a pair of spaced apart headers 02a and 02b connected to two distant and opposite end portions of a heat exchanger core 03. The heat exchanger core 03 is configured of a plurality of heat exchange elements, particularly, heat exchange tubes 03a through which a first heat exchange fluid flows and a plurality of fin elements 03b lodged between the adjacent heat exchange tubes 03a. More specifically, the heat exchanger 01 is a radiator, and a fan system directs air over the heat exchanger core 03. Such configuration facilitates heat exchange between the first heat exchanging fluid flowing inside the heat exchange tubes 03a and air flowing outside the heat exchange tubes 03a.

The heat exchanger 01 further includes a pair of heat exchanger tanks 06a and 06b, hereinafter referred to as tanks corresponding to the pair of headers 02a, 02b, wherein crimping connection is formed between the tanks 06a, 06b and the corresponding headers 02a, 02b for configuring a header-tank assembly 09a, 09b. The tanks 06a, 06b are capable of receiving first heat exchanging fluid, often, pressurized heat exchanging fluid and the tanks 06a, 06b in conjunction with the corresponding headers 02a, 02b facilitate distribution of the first heat exchange fluid to and collection of the first heat exchange fluid from the heat exchange tubes of the heat exchange core 03 respectively. Particularly, the first heat exchange fluid ingresses the tank 06a via an inlet 5a, passes through the heat exchange tubes 03a, reaches the tank 06b and egresses out of the tank 06b via an outlet 05b. In case the first heat exchange fluid leaks through the connection between the headers 02a, 02b and the corresponding tanks 06a, 06b, the efficiency and performance of the heat exchanger 01 is detrimentally impacted. According, an airtight and sealed connection is required between the tanks 06a, 06b and the corresponding headers 02a, 02b. To achieve sealed connection between the tank 06a, 06b and the corresponding header 02a, 02b, a gasket is disposed between the tank 06a, 06b and the corresponding header 02, 02b. Specifically, the conventional header-tank assembly 09a, 09b and assembly process therefor involves receiving the gasket 08 in the header 02a, 02b. Thereafter, configuring crimping connection between the header 02a, 02b and the corresponding tank 06a, 06b. Particularly, tabs 02c, 02d configured on the headers 02a, 02b are folded over foot portions 07a, 07b of the respective tanks 06a, 06b to configure crimping connection between the headers 02a, 02b and the corresponding tanks 06a, 06b with the gasket 08a, 08b disposed there between. However, during crimping, displacing and compressive forces exerted on the gasket 08a, 08b may cause displacement of the gasket 08a, 08b from a desired position thereof between the foot portion of the tanks 06a, 06b and the corresponding header 02a, 02b and pinching of the gasket 08a, 08b is common. Further, the gasket 08a, 08b is generally of improper size and is required to be adjusted depending upon size of the tank 06a, 06b and the corresponding header 02a, 02b to prevent pinching of the gasket 08. Accordingly, in case of the conventional header-tank assembly 09a, 09b and the assembly process there for, there are comparatively higher chances of pinching of the gasket 08a, 08b. The pinching of the gasket 08a, 08b have several drawbacks, for example, the pinching of the gasket 08a, 08b may cause damage to the gasket 08a, 08b and leakage may occur through the damaged gasket, thereby adversely impacting efficiency and performance of the heat exchanger 01. Further, conventional header-tank assembly 01 and the assembly process therefor requires more number of assembly steps and is complicated.

Accordingly, there is a need for a header-tank assembly and assembly process therefor that prevents pinching of a gasket between a tank and a corresponding header thereof by eliminating the chances of displacement of the gasket during crimping or assembly of the tank over the header or due to selection of improper sized gasket. Further, there is a need for a header-tank assembly and assembly process therefor that prevents pinching of the gasket and as such all drawbacks associated with pinching of the gasket. Specifically, there is a need for a header-tank assembly that addresses issues such as damage to the gasket, reduced service life and reliability issues associated with the gasket due to pinching of the gasket, in-efficient operation and performance of the heat exchanger due to leakage of heat exchange fluid through the damaged gasket. Furthermore, there is a need for a header-tank assembly and an assembly process therefor that reduces the assembly steps and assembly time involved in assembling of a tank over a corresponding header of a heat exchanger, with a gasket disposed between a foot portion of the tank and the header.

An object of the present invention is to provide a header-tank assembly and assembly process therefor that prevents pinching of a gasket due to displacement of the gasket during assembly or selection of improper sized gasket, thereby preventing drawbacks associated with the pinching of the gasket.

Another object of the present invention is to provide a header-tank assembly and assembly process therefor that provides ease of assembly, reduces assembly time and number of assembly steps.

Yet another object of the present invention is to provide a header-tank assembly that configures secure sealed connection between a tank and the corresponding header, thereby improving efficiency and performance of the heat exchanger by preventing leakage of heat exchange fluid through connection between header and the corresponding tank.

Still another object of the present invention is to provide a header-tank assembly that enhances service life and reliability of gasket, thereby improving service life and reliability of the heat exchanger.

Yet another object of the present invention is to provide a header-tank assembly that involves fewer parts and accordingly is inexpensive, reliable, and convenient to assembly. In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

A header-tank assembly is disclosed in accordance with an embodiment of the present invention. The header-tank assembly includes a tank, a gasket and a header. The tank includes a plurality of first engagement elements configured thereon. The gasket includes a plurality of second engagement elements configured thereon. The second engagement elements are complimentary to and engages with the first engagement elements to mount the gasket along a periphery of a foot portion of the tank. The header is crimped to the foot portion of the tank with the gasket disposed between the header and the foot portion of the tank.

In accordance with a preferred embodiment of the present invention, the second engagement elements are formed on connection elements outwardly extending from the gasket.

Specifically, the connection elements are configured at corners of the gasket and do not interfere with crimping of the header over the foot portion of the tank while configuring connection between the first and the second engagement elements.

Particularly, the connection elements and the second engagement elements formed on the connection elements are integrally formed with the gasket and are configured of same material as that of the gasket.

Generally, the connection elements are having cross-sectional dimension less than that of the gasket. Particularly, the first engagement elements and the corresponding complimentary second engagement elements are selected from a group comprising snap fit engagement elements, loop-rod type engagement elements and the likes.

In accordance with an embodiment of the present invention, the tank further includes cut-out portions configured at corners thereof for guiding the connection elements such that the second engagement elements configured on the connection element are guided to the first engagement elements.

A heat exchanger tank is disclosed in accordance with an embodiment of the present invention. The heat exchanger tank includes a plurality of first engagement elements that engages with a plurality of second engagement elements configured on a gasket to mount the gasket along periphery of a foot portion of the heat exchanger tank.

Generally, the first engagement elements are located substantially on opposite sides of the tank with respect to the gasket and the header.

In accordance with an embodiment of the present invention, the first engagement elements are located substantially on a side of the tank that is adjacent to and orthogonal to a side accommodating the gasket and the header.

Specifically, the connection between the first engagement elements and the corresponding complimentary second engagement elements is releasable engagement.

Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

FIG. 1a illustrates a schematic representation of a heat exchanger in accordance with a prior art;

FIG. 1b illustrates an exploded sectional view of a conventional header-tank assembly of the heat exchanger of FIG. 1a;

FIG. 1c illustrates another exploded view of the conventional header-tank assembly of FIG. 1b;

FIG. 2a illustrates a schematic representation of a header-tank assembly in accordance with an embodiment of the present invention;

FIG. 2b illustrates a schematic representation of a header-tank assembly in accordance with another embodiment of the present invention, wherein connection elements with second engagement elements formed thereon are configured at corners of a gasket;

FIG.2c illustrates the schematic representation of the header-tank assembly of FIG. 2b, wherein the second engagement elements are depicted engaging with first engagement elements configured on the tank;

FIG. 3 illustrates a schematic representation of a header-tank assembly, wherein first and second engagement elements in accordance with another embodiment are depicted engaging with each other; and FIG. 4 illustrates a schematic representation of a tank of a header-tank assembly in accordance with still another embodiment of the present invention, wherein corners of the tank are configured with cut-out portions for guiding the connection elements.

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

A header-tank assembly and an assembly process for configuring an airtight connection between a tank and a corresponding header by securely holding a gasket between the tank and the header during crimping or assembly of the tank over the header is disclosed. The header-tank assembly includes a plurality of clamping elements, particularly, connection elements with engagement elements configured thereon. The connection elements are formed on the gasket, particularly at the corners of the gasket. The engagement elements configured on the connection elements are engaged with the complimentary engagement elements configured on the tank to securely mount the gasket in a position. Particularly, engagement between the complimentary engagement elements configured on the tank and the gasket securely mounts the gasket along periphery of a foot portion of the tank, thereby retaining the gasket in the desired position between the foot portion of the tank and the header. Such configuration prevents displacement of the gasket even in presence of displacing and compressive forces exerted on the gasket during the crimping and assembly and also adjusts the gasket according to size of the header and the tank to prevent pinching of the gasket. Although, the header-tank assembly of the present invention is used for configuring sealed connection between the header and the tank of the heat exchanger used in vehicles. However, the present invention is also applicable for any other applications where gaskets are required to configure secure sealed connection between engaging parts and it is required to prevent pinching of the gasket, thereby preventing drawbacks associated with pinching of the gasket. FIG. 1a illustrates a schematic representation of a heat exchanger 01 configured with a conventional header-tank assembly 09a, 09b. FIG.1b and FIG.1c illustrate the conventional header-tank assembly 09a, 09b, wherein a gasket 08a, 08b is disposed between a header 02a, 02b and a foot portion 07a, 07b of a corresponding tank 06a, 06b. In the conventional header-tank assembly 09a, 09b, the pinching of the gasket 08a, 08b is common, due to displacement of the gasket 08a, 08b during crimping of the header 02a, 02b over the tank 06a, 06b or selection of inappropriate sized gasket 08a, 08b. The pinching of the gasket 08a, 08b may cause damage to the gasket 08a, 08b and reduce service life and reliability of the gasket 08a, 08b. Further, leakage of heat exchange fluid through damaged gasket may adversely impact performance and efficiency of the heat exchanger 01.

The present invention envisages a header-tank assembly of a pair of header- tank assemblies 100a, 100b for a heat exchanger such as for example, a radiator. More specifically, the heat exchanger generally includes a first header-tank assembly and a second header-tank assembly, wherein the first header-tank assembly 100a and the second header-tank assembly 100b are respectively configured at extreme end portions of a heat exchanger core of the heat exchanger. As the first and the second header-tank assemblies are identical, every embodiment disclosed henceforth for the first header-tank assembly 100a and the elements configuring the first header- tank assembly 100a may also applicable for the second header-tank assembly 100b and elements configuring the header-tank assembly 100b. For sake of brevity of present document, enlarged views depicting the details of only the first header-tank assembly 100a are illustrated in the Figures and described in the forthcoming description.

As illustrated in FIG. 2a - FIG. 4, the header-tank assembly 100a includes a tank 10a, a gasket 20a and a header 30a (illustrated in FIG. 4). The tank 10a includes a plurality of first engagement elements 12a configured thereon. Specifically, the first engagement elements 12a are located substantially on opposite sides of the tank 10a with respect to the gasket 20a and the header 30a. More specifically, the first engagement elements 12a are located substantially on a side of the tank 10a that is adjacent to and orthogonal to a side accommodating the gasket 20a and the header 30a. The gasket 20a includes a plurality of second engagement elements 22a configured thereon. The second engagement elements 22a are complimentary to and engages with the first engagement elements 12a to mount the gasket 20a along a periphery of a foot portion 14a of the tank 10a, thereby retaining the gasket 20a in a desired position, particularly between the foot portion 14a of the tank 10a and the corresponding header 30a even during crimping of the header 30a over the tank 10a. The connection between the first engagement elements 12a and the corresponding complimentary second engagement elements 22a is releasable engagement. FIG. 2a illustrates the header-tank assembly 100a depicting the second engagement elements 22a configured on the gasket 20a directly engaged with the first engagement elements 12a configured on the tank of the header tank assembly 100a. The header 30a is crimped to the foot portion 14a of the tank 10a with the gasket 20a securely held between the foot portion 14a of the tank 10a and the corresponding header 30a. With such configuration, the gasket 20a is retained in the desired position between the foot portion 14a of the tank 10a and the corresponding header 30a, irrespective of various displacing and compressive forces acting on the gasket 20a during the crimping of the header 30a over the foot portion 14a of the tank 10a. With such configuration, the displacement of the gasket 20a and accordingly the pinching of the gasket 20a between the tank 10a and the header 30a is eliminated. As such, the drawbacks associated with the pinching of the gasket 20a, such as damage to the gasket 20a are eliminated and the service life of the gasket 20a is improved. Further, the leakage of heat exchange fluid leaking through damaged gasket 20a is eliminated and performance and efficiency of the heat exchanger configured with the header-tank assembly 100a of the present invention is not adversely impacted as the pinching of the gasket 20a is eliminated.

In accordance with preferred embodiment of the present invention as illustrated in FIG.2b, FIG. 2c and FIG. 3, the header-tank assembly 100a includes a plurality of connection elements 24a that outwardly extend from the gasket 20a. Particularly, the connection elements 24a are configured at the corners of the gasket 20a and each connection element 24a includes at least one, second engagement element 22a formed thereon. The connection elements 24a enable the second engagement elements 22a to reach and engage with the first engagement elements 12a formed on the tank 10a to securely mount the gasket 20a along the periphery of the foot portion 14a of the tank 10a, thereby retaining the gasket 20a in the desired position, particularly between the foot portion 14a of the tank 10a and the corresponding header 30a. FIG. 2b is a schematic representation of the header-tank assembly 100a with the second engagement elements 22a formed on the connection elements 24a disengaged from the first engagement elements 12a. FIG.2c is a schematic representation of the header-tank assembly 100a with the second engagement elements 22a configured on the connection elements 24a engaged with the first engagement elements 12a configured on the tank 10. In accordance with an embodiment, at least one of the connection elements 24a is having a single-piece construction, else the at least one of the connection elements 24a is configured by joining a plurality of elements.

In accordance with an embodiment of the present invention, the second engagement elements 22a are formed at extreme ends of the connection elements 24a. The connection elements 24a and the second engagement elements 22a configured thereon are integrally formed with the gasket 20a and as such are of the same material as that of the gasket 20a. In accordance with an embodiment, the connection elements 24a are having cross-sectional dimension less than that of the gasket 20a. In accordance with another embodiment of the present invention, the connection elements 24a are secured to the gasket 20a and are configured of different material than that of the gasket 20a. As the connection elements 24a are configured at the corners of the gasket 20a, the connection elements 24a do not interfere with crimping of the header 30a over the foot portion 14a of the tank 10a while configuring connection between the first and the second engagement elements 12a, 22a. However, the present invention is not limited to any particular configuration and material of the connection elements 24a, the number and placement of the connection elements 24a as far as the connection elements 24a enable the second engagement elements 22a to reach and engage with the first engagement elements 12a and securely mount the gasket 20a in the desired position, without interfering with crimping of the header 30a over the foot portion 14a of the tank 10a. The header 30a receives the heat exchange tubes 32a in the apertures configured on the header 30a. The engagement between the first engagement elements 12a and the second engagement elements 22a can serve as an arrangement for temporarily positioning the gasket 20a in the desired position, particularly, between the foot portion 14a of the tank 10a and the corresponding header 30a, until the header 30a is crimped to the corresponding tank 10a. In one example, the first engagement elements 12a and the second engagement elements 22a can be disengaged from each other once the header 30a is crimped to the corresponding tank 10a. In another example, the connection elements 24a can be severed after the header 30a is crimped to the corresponding tank 10a.

The second engagement elements 22a engage with the complimentary first engagement elements 12a configured on the tank 12 and securely mounts the gasket 20 in position. Particularly, the engagement between the first engagement elements 12a and the complimentary second engagement elements 22a configured on the tank 10a and the gasket 20a respectively, securely mounts the gasket 20a along periphery of the foot portion 14a of the tank 10a in the desired position, particularly, between the foot portion 14a of the tank 10a and the header 30a and retains the gasket 20a in the desired position. The first engagement elements 12a and the corresponding complimentary second engagement elements 22a are selected from a group comprising snap fit engagement elements, loop-rod type engagement elements and the likes. FIG. 3 illustrates a schematic representation of the header-tank assembly 100a in accordance with another embodiment, wherein the first engagement elements 12a and the second engagement elements 22a are having another configuration and are engaging with each other. However, the present invention is not limited to any particular configuration and placement of the first engagement elements 12a and the second engagement elements 22a as far as the first engagement elements 12a and the second engagement elements 22a engage with each other to mount the gasket 20a in place without interfering with crimping of the header 30a over the foot portion 14a of the tank 10a. In accordance with an embodiment as illustrated in FIG. 2a, the first engagement elements 12a can be configured close to the foot portion 14a of the tank 10a or on the foot portion 14a of the tank 10a and the second engagement elements 22a configured on the gasket 20a directly engages with the first engagement elements 12a. Alternatively, the first engagement elements 12a are configured away from the foot portion 14a of the tank 10a and the connecting elements 24a configured at the corners of the gasket 20a enables engagement between the second engagement elements 22a formed at the free ends of the connecting elements 24a and the first engagement elements 12a configured away from the foot portion 14a of the tank 10a as illustrated in FIG. 2c.

The tank 10a further includes cut-out portions 16a configured at corners thereof for guiding the connection elements 24a such that the second engagement elements 22a configured on the connection element 24a are guided to reach the first engagement elements 12a. FIG. 4 illustrates a schematic representation of the tank 10a of the header-tank assembly 100a, wherein corners of the tank 10a are configured with the cut-out portions 16a for guiding the connection elements 24a configured at the corners of the gasket 10a so as to configure engagement between the second engagement elements 22a configured on the connection elements 24a and the first engagement element 12a.

In accordance with an embodiment of the present invention, the gasket 20a as well as the connection elements 24a may stretch as the first engagement elements 12a and the second engagement elements 22a engage with each other. Such configuration not only securely mounts the gasket 20a over the foot portion 14a of the tank 10a at the desired position and prevents displacement of the gasket 20a from the desired position but also adjusts the gasket 20a according to size of the header 30a and the tank 10a, thereby preventing pinching of the gasket 20a caused due to selection of inappropriate size of the gasket 20a. In one embodiment, the gasket 20a can be pre-assembled over the foot portion 14a of the tank 10a, and such pre assembled tank and gasket assembly with the gasket 20a held in position is mounted over the header 30a by crimping operation. With such configuration, the step of aligning the gasket 20a with respect to the tank 10a and the header 30a is eliminated, accordingly, the assembly time is reduced and assembly is convenient. A heat exchanger tank 10a is disclosed in accordance with an embodiment of the present invention. The heat exchanger tank 10a includes a plurality of first engagement elements 12a that engages with a plurality of second engagement elements 22a configured on a gasket 20a to mount the gasket 20a in place, particularly, along a periphery of a foot portion 14a of the heat exchanger tank 10a to retain the gasket 20a between the foot portion 14a of the heat exchanger tank 10a and the corresponding header 30a.

Several modifications and improvement might be applied by the person skilled in the art to the header-tank assembly 100a, 100b as defined above, and such modifications and improvements will still be considered within the scope and ambit of the present invention, as long as it comprises a tank, a gasket and a header. The tank includes a plurality of first engagement elements configured thereon. The gasket includes a plurality of second engagement elements configured thereon. The second engagement elements are complimentary to and engages with the first engagement elements to mount the gasket along a periphery of a foot portion of the tank. The header is crimped to the foot portion of the tank with the gasket disposed between the header and the foot portion of the tank.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described herein.

In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means.