METHOD OF ATTACHING A TUBE TO A FIN

Abstract: This invention relates to a method of attaching a fluid conducting metal tube (12) a heat dissipating metal fin (14) that includes the following steps. A metal tube (12) is formed having a generally elliptical cross-section having first similar­ ly curved surfaces (22-22) at opposite ends of a major axis thereof and second similarly curved surfaces (24-24) at opposite ends of a minor axis thereof. A heat dissipating metal fin (14) is formed. An elliptically shaped collar (20) is formed on the fin, this collar providing an opening through the fin and being at least about 1-1/2 times the thickness of the metal forming the fin. The tube is fitted inside the opening of the fin so that areas of these two elements are juxtaposed. The tube is expanded along the major axis so as to bring the first similarly curved surfaces at opposite ends thereof into contact with portions of the collar in juxtaposi­ tion therewith. Expansion of the tube is continued along the major axis and initiated along the tube from opposite ends of the major axis toward the surfaces which were defined at opposite ends of the minor axis of the tube. In this manner, any juxtaposed area of the tube and the collar are subjected to an expansion process in which the tube is moved towards the collar, the two elements are brought into contact with one another, and then the two elements are expanded together. The expansion process is progressively terminated between the tube and collar from the major axis of the tube toward the minor axis thereof. The termination occurs in such juxtaposed areas as those areas reach a condition in which the tube is being deformed plastically but the collar is still being deformed elastically.

Description: This application is directed to a method of attaching a tube to a plate and is particularly concerned with a method of attaching a fluid conducting metal tube to a heat dissipating metal fin or header. Many similar connections are made in a single radiator structure in order to have a unique radiator construction. One present day known way of making radiators is a so-called mechanically assembled radiator. In such a mechanically assembled radiator, tubes having a round cross-section are expanded uniformly about their circumference into contact with a surface area of a heat dissipating metal fin encircling the same. This type of construction is well known in the art. Other constructions for radiators include oval and elliptical cross-section tubes which are brazed to a heat dissipating metal fin. Such tube radiator configurations create a compact heat exchanger which is optimized with respect to cost and weight while minimizing the total radiator's volumetric displacement. In a mechanically assembled, according to the precharacterising parts of claims 1, 2 and 6, elliptical tube radiator, uniform expansion of an elliptical tube into a heat dissipating fin, according to the precharacterising parts of claims 1, 2 and 6, as suggested in FR-A-2 380 088, has been found not to work. The reason for this is that the expansion process results in poor tube contact with surrounding collars as well as splits in tubes and collars. The present invention therefore seeks to provides a method of expanding an elliptical tube into contact with a heat dissipating metal fin or header which ensures excellent heat conducting contact as well as good mechanical contact therebetween. According to one aspect of the invention, there is provided a method of attaching a fluid conducting metal tube to a heat dissipating metal fin, which comprises the steps of forming a metal tube having a generally elliptical cross-section, forming a heat dissipating metal fin with an elliptical opening of a size slightly larger than the elliptical cross-section of the tube, the opening being defined by a raised collar having a thickness at least one and a half times as great as the thickness of the metal forming the fin, fitting the tube inside the opening in the fin so that areas of the tube and the collar are juxtaposed, and expanding the tube into contact with the collar, characterised in that the expansion the tube comprises the steps of first expanding the tube along only the major axis so as to bring first similarly curved surfaces at opposite ends of the major axis of the cross section into contact with the juxtaposed portions of the collar, continuing expansion along the major axis and initiating expansion of the tube from opposite ends of the major axis toward second curved surfaces at opposite ends of the minor axis of the tube to expand the regions of contact between the tube and the collar progressively from the first curved surfaces at the ends of the major axis towards the second curved surfaces at the ends of the minor axis, and terminating the expansion process of the tube and the collar progressively from the major axis of the tube toward the minor axis thereof as juxtaposed areas of the tube and the collar reach a condition in which the tube is being deformed plastically but the collar is still being deformed elastically. The invention further provided a method as hereinafter set forth in Claim 2 for attaching a fluid conducting metal tube to a heat dissipating metal header, and to apparatus as set forth in Claim 6, for attaching a fluid conducting metal tube to a heat dissipating metal fin or header. When the process of the present invention is repeated a number of times, many tubes may be connected to many heat dissipating metal fins. In such a manner, a radiator construction can be built up. However, the process is an excellent one for joining any elliptical cross-section tube to a metal fin to construct any type of heat dissipating device. In accordance with a preferred embodiment of this invention, the ratio of the length of the major axis to the length of the minor axis is above 3:1 and most preferably is above 3.7:1. The invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 is a partial elevation view of a mechanically assembled, elliptical tube, aluminum radiator which has tubes thereof attached to heat dissipating fins thereof in accordance with the method of this invention; Figure 2 is a plan view in cross-section taken along line II-II of Figure 1; Figure 3 is a front elevation view of a "bullet" used to expand the elliptical tube into contact with the fin in accordance with the teachings of the method of this invention; Figure 4 is a plan view of the bullet of Figure 3; Figure 5 is a cross-section view of the bullet of Figure 3 taken along line V-V of that Figure; Figure 6 is a side elevation view of the bullet of Figure 3; and Figure 7, 8 and 9 are enlarged schematic views showing the method of this invention in various steps as it expands a metal tube into contact with a metal fin. In Figure 1, an elevation view is shown of a portion of a mechanically assembled, elliptical tube, aluminum radiator, generally defined by the numeral 10. This radiator has a plurality of elliptical tubes 12-12 mechanically assembled to a plurality of heat dissipating metal fins 14-14 in accordance with the teachings of the method of this invention. Respective ends of the tubes 12 are connected to headers 16, only one shown in Figures 1-2, which in turn can be connected to a plastic housing in order to define a container for liquid which is to flow through the fluid conducting tubes. The tubes 12 can be bonded to the headers 16 in the same manner as the tubes are bonded to the fins. As best seen in Figures 1-2, each fin 14 has a plurality of tabs 18-18 associated therewith. These tabs serve as spacers, as best shown in Figure 1, to define fin pitch, that is, fin density, and to serve as air vanes to create better air flow to more critical heat transfer areas of the radiator 10. The tab can also provide a mixing potential for the air which allows the design of the radiator 10 to be optimized for thickness of fin and width of fin. The fin also has associated therewith a plurality of elliptically shaped collars 20-20. The fin collars and tabs can be made by punching out these elements as the fin strip 14 is being made. The fin strip can be made from a hardened aluminum material such as AA-3003-H19 material. In accordance with the teachings of the method of this invention, a fluid conducting metal tube 12 is attached to a heat dissipating metal fin 14 in the following manner. The attachment provides excellent mechanical support between the two elements and provides excellent physical contact therebetween for heat transfer purposes. The metal tube 12 is formed from aluminum AA-3003-0 so as to have a generally elliptical cross-section. The easiest way to form the tube is to make a seamless, extruded drawn and formed tube. The tube cross-sectional geometry is elliptical in nature. As seen only in Figure 7, the metal tube has first similarly curved surfaces 22-22 at opposite ends of a major axis thereof and second similarly curved surfaces 24-24 at opposite ends of a minor axis thereof. In accordance with the teachings of a preferred embodiment, the ratio of the length of the major axis to the minor axis is 3.7:1. We generally prefer to have this ratio be at about 3:1 or higher to get the very best results from our process. A heat dissipating metal fin 14 is formed. In accordance with the teachings of a preferred embodiment, the fin has associated therewith a plurality of tabs 18-18 and collars 20-20 which can be deformed from the fin surface using suitable dies, preferably stamping dies. Each of the collars 20-20, as originally formed, provide an opening through the fin 14. In the relatively thin fin material, these collars are at least about 1-1/2 times the thickness of the metal forming the fin. However, in the case of the heavier gauge metal used to form the header 16, there is no need of providing a collar in order to carry out the method of this invention. As originally formed, each opening provided by the collar 20 of the fin 14 is of a size slightly larger than the elliptical cross-section of a corresponding tube 12. Therefore, as initially positioned, and as shown only in Figure 7, there can be a slight space or opening 26 between a tube which has been placed inside the opening of the collar so that areas of the tube and the collar are juxtaposed, as shown in Figure 7. The process of this invention is carried out by utilization of a bullet, generally designated by the numeral 30, in Figures 3-6. The bullet 30 is forced through the tube 12 in order to expand the same into contact with one or more of the fins 14-14. In accordance with the teachings of the method of this invention, the bullet may be forced or pulled through the tube in either direction. However, it is preferred to have the bullet moved through the tube in a direction opposed to the direction in which the collars 20-20 are facing from the fins 14-14. In the radiator 10, shown in Figure 1, the preferred direction of movement of the bullet would be downwardly, as viewed in that direction. The reason for this direction of movement is that by directing the bullet in a direction opposing the upturned edge of the collar, the highest stress will be transmitted to the mating surfaces at right angles resulting in a tight, high contact joint. In accordance with the teachings of the method of this invention, tube 12 is expanded along its major axis so as to bring the first similarly curved surfaces 22-22 therein at opposite ends thereof into contact with portions of the collar 20 in juxtaposition therewith. This first expansion is brought about by engagement of the tubes surface to be expanded by first engaging surfaces 32-32 of the bullet 30. As best seen in Figure 8, this first expansion of the tube 12 along its major axis causes the first similarly curved surfaces 22-22 to move into contact with portions of the collar 20 in juxtaposition therewith. This action also causes the generally elliptical shape of the tube to be changed into an oval shape, as shown in Figure 8, in which spaces 34-34 are left between areas of the tube formerly at the opposite ends of the minor axis thereof and juxtaposed areas of the collar 20. Second engaging surfaces 36-36 of the bullet 30 then engage the area of the tube 12 previously engaged by the first engaging surfaces 32-32 of the bullet. This engagement of the surface with the second engaging surfaces 36-36 continues expansion along the major axis of the elliptical cross-section tube and initiates expansion of the tube 12 from opposite ends of the major axis toward the surfaces 24-24 which were defined at opposite ends of the minor axis of the tube. In this manner, any juxtaposed area of the tube and the collar are subjected to an expansion process in which the tube is moved initially towards the collar, the two elements are then brought into contact with one another, and then the two elements are expanded together. In accordance with the teachings of the method of bis invention, the expansion process for the tube and collar is progressively terminated as that process moves from the major axis of the tube toward the minor axis thereof. The expansion process then is one which is not accomplished simultaneously about the entire perimeter of the tube at one location, but rather occurs progressively from each end of the major axis toward the minor axis of the elliptical tube at any given cross-section. The expansion process is terminated when juxtaposed areas of the tube and the collar reach a condition in which the tube is being deformed plastically, but the collar is still being deformed elastically. In this manner, since the tube is in a plastic deformation state, it remains in the deformed position. However, since the deformation of the collar is still elastic, the collar wants to return to its original position and applies force on the outside of the tube. In such a manner, an excellent mechanical contact is made between the deformed tube and collar, the mechanical contact also providing a contact which has excellent thermal conductivity properties. In this manner, an optimum fin/tube heat transfer interface is created. Generally, we desire approximately a 0.0508-0.1016 mm (0.002-0.004 inch) interference at the interface between the tube and the collar but the outerface can be as much as 0.012 inch or more. While this specification has described the manner in which a single tube is bonded to a single collar of a single fin strip, it is, of course, readily apparent that the bullet 30 being moved through an individual tube will perform the same process along the length of the tube to bring each individual tube into bonding contact with the surrounding collar. In such a manner, a mechanically assembled, elliptical tube radiator construction can be formed.

Claims: A method of attaching a fluid conducting metal tube to a heat dissipating metal fin, which comprises the steps of forming a metal tube (12) having a generally elliptical cross-section, forming a heat dissipating metal fin (14) with an elliptical opening of a size slightly larger than the elliptical cross-section of the tube (12), the opening being defined by a raised collar having a thickness at least one and a half times as great as the thickness of the metal forming the fin, fitting the tube (12) inside the opening in the fin (14) so that areas of the tube (12) and the collar (20) are juxtaposed, and expanding the tube (12) into contact with the collar (20), characterised in that the expansion the tube (12) comprises the steps of first expanding the tube (12) along only the major axis so as to bring first similarly curved surfaces (22) at opposite ends of the major axis of the cross section into contact with the juxtaposed portions of the collar (20), continuing expansion along the major axis and initiating expansion of the tube (12) from opposite ends of the major axis toward second curved surfaces (24) at opposite ends of the minor axis of the tube (12) to expand the regions of contact between the tube (12) and the collar (20) progressively from the first curved surfaces (22) at the ends of the major axis towards the second curved surfaces (24) at the ends of the minor axis, and terminating the expansion process of the tube (12) and the collar (20) progressively from the major axis of the tube (12) toward the minor axis thereof as juxtaposed areas of the tube (12) and the collar (20) reach a condition in which the tube (12) is being deformed plastically but the collar (20) is still being deformed elastically. A method of attaching a fluid conducting metal tube to a heat dissipating metal header, which comprises the steps of forming a metal tube (12) having a generally elliptical cross-section, forming a heat dissipating metal header (14) with an elliptical opening, the edges of the opening forming a collar of a size slightly larger than the elliptical cross-section of the tube (12), fitting the tube (12) inside the opening in the header (14) so that areas of the tube (12) and the collar (20) are juxtaposed, and expanding the tube (12) into contact with the collar (20), characterised in that the expansion the tube (12) comprises the steps of first expanding the tube (12) along only the major axis so as to bring first similarly curved surfaces (22) at opposite ends of the major axis of the cross section into contact with the juxtaposed portions of the collar (20), continuing expansion along the major axis and initiating expansion of the tube (12) from opposite ends of the major axis toward second curved surfaces (24) at opposite ends of the minor axis of the tube (12) to expand the regions of contact between the tube (12) and the collar (20) progressively from the first curved surfaces (22) at the ends of the major axis towards the second curved surfaces (24) at the ends of the minor axis, and terminating the expansion process of the tube (12) and the collar (20) progressively from the major axis of the tube (12) toward the minor axis thereof as juxtaposed areas of the tube (12) and the collar (20) reach a condition in which the tube (12) is being deformed plastically but the collar (20) is still being deformed elastically. A method as claimed in Claim 1, in which the raised collar (20) extends above one surface of the fin and the deformation process of the tube takes place in a direction downwardly from the upstanding collar toward the fin. A method as claimed in any preceding claim, wherein the ratio of the length of the major axis to the minor axis is at least 3 : 1. A method as claimed in Claim 4, wherein the ratio of the length of the major axis to the minor axis is 3.7 : 1. Apparatus for attaching a fluid conducting metal tube to a heat dissipating metal plate, wherein the tube (12) has a generally elliptical cross-section and is received within a slightly larger elliptical opening in a plate (14) which has a collar (20) surrounding the opening so that areas of the tube (12) and the collar (20) are juxtaposed, the apparatus comprising a bullet (30) to be driven down the tube (12) in order to expand the tube (12) into contact with the collar (20), characterised in that the bullet (30) comprises a first section (32) for expanding the tube (12) along only the major axis so as to bring first similarly curved surfaces (22) at opposite ends of the major axis of the cross section into contact with the juxtaposed portions of the collar (20), and a second section (36) spaced from the first section (32) in the direction of travel of the bullet down the tube (12) for continuing expansion along the major axis and initiating expansion of the tube (12) from opposite ends of the major axis toward second curved surfaces (24) at opposite ends of the minor axis of the tube (12) to expand the regions of contact between the tube (12) and the collar (20) progressively from the first curved surfaces (22) at the ends of the major axis towards the second curved surfaces (24) at the ends of the minor axis, the second section (36) being dimensioned and shaped to terminate the expansion of the tube (12) and the collar (20) progressively from the major axis of the tube (12) toward the minor axis thereof as juxtaposed areas of the tube (12) and the collar (20) reach a condition in which the tube (12) is being deformed plastically but the collar (20) is still being deformed elastically.

Inventors: PARK, KWANG HYUN, VELING, THOMAS ROBERT, WIKLUND, GEORGE CARL
Applicants: FORD FRANCE SOCIETE ANONYME, FORD MOTOR COMPANY, FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1986
Main classification: B21D53
IPC codes: F28F1, F28F9, B21D53