Heat exchanger and method of making the same

1. A side plate for use with a heat exchanger, the heat exchanger including a pair of spaced, generally parallel headers, a plurality of spaced, generally parallel tubes extending between and in fluid communication with an interior of said headers and fins extending between the tubes, the side plate comprising:

first and second ends, at least one of the ends contoured to provide at least one localized contact bonded to one of the headers and the at least one contoured end being bonded to only an exterior of one of the headers; and

an intermediate portion having a width and extending between the ends,

wherein each localized contact has a contact width that is less than ⅕ the width of the intermediate portion, and wherein only the each localized contact engages the header to form a break point adjacent the header for separating the side plate and header as a result of thermal expansion and contraction of the heat exchanger.

2. The side plate of claim 1 wherein each of the first and second ends are shaped to provide at least one localized contact bonded to the headers.

3. The side plate of claim 1 wherein the first end is V-shaped to provide one localized contact.

4. The side plate of claim 1 wherein the first end is U-shaped to provide two localized contacts.

5. The side plate of claim 1 wherein the fins contact a bottom surface of the side plate.

6. The side plate of claim 5 further comprising a tab extending substantially perpendicularly therefrom and contacting a side of the fins.

7. The side plate of claim 6 wherein the tab contacts serpentine fins.

8. The side plate of claim 1 wherein the first end is bonded to a cylindrical header.

9. The side plates of claim 1 wherein the localized contact is shaped to provide a line contact or a point contact with the header.

10. The side plate of claim 1 wherein a portion of the at least one localized contact includes a first side and a second side, the first side and the second side converge in a direction from the intermediate portion to the break point.

11. A side plate for use with a heat exchanger, the heat exchanger including a pair of spaced, generally parallel headers, a plurality of spaced, generally parallel tubes extending between and in fluid communication with an interior of said headers and fins extending between the tubes, the side plate comprising:

first and second ends, at least one shaped to provide at least one localized contact bonded to one of the headers; and

an intermediate portion having a width overlying an outermost one of said fins,

wherein each localized contact is sized to separate from the header under relatively low tension applied by the thermal expansion and contraction of the heat exchanger under normal operating conditions, and wherein the shaped end is tapered to define a point of narrowing such that separation from the header occurs at the point of narrowing.

12. The side plate of claim 11 wherein each of the first and second ends are shaped to provide at least one localized contact bonded to the headers.

13. The side plate of claim 11 wherein the first end is V-shaped to provide one localized contacts.

14. The side plate of claim 11 wherein the first end is U-shaped to provide two localized contacts.

15. The side plate of claim 11 wherein the fins contact a bottom surface of the side plate.

16. The side plate of claim 15 further comprising a tab extending substantially perpendicularly therefrom and contacting a side of the fins.

17. The side plate of claim 16 wherein the tab contacts serpentine fins.

18. The side plate of claim 11 wherein the first end is bonded to a cylindrical header.

19. The side plates of claim 11 wherein the localized contact is shaped to provide a line contact or a point contact with the header.

20. A method of making a heat exchanger comprising the steps of:

assembling the components of a heat exchanger core to have a pair of spaced parallel headers, spaced tubes extending between the headers, a side plate extending between the headers at a side of the core, and fins extend between the tubes and between the side plate and an outermost one of the tubes;

locating the side plate between the headers by abutting at least one localized contact formed on an end of the plate against one of the headers; and

bonding the localized contact to the header during a bonding process for the core such that subjecting the heat exchanger to operating temperatures results in separation of the localized contact and the header at the point of contact between the localized contact and the header.

21. The method of claim 20 wherein the bonding step includes bonding the localized contact at each end of the side plate.