Brazed headerless core assembly for a modular heat exchanger

1. A brazed headerless core assembly and a pre-existing heat exchanger assembly from which a core assembly has been removed such that header members with spaced-apart apertures therein remain of the pre-existing heat exchanger, the brazed headerless core assembly having a tube end spacing pattern corresponding to the spacing of the apertures of the header members to enable the brazed headerless core assembly to be assembled with the header members and fluidically sealed thereto with resilient sealing means, the brazed headerless core assembly comprising:

substantially parallel tubes, each of the tubes having an oblong cross-section defining oppositely-disposed planar surfaces that are spaced from a longitudinal axis of the tube, each of the tubes having oppositely-disposed tube ends so that each adjacent pair of tubes has adjacent pairs of tube ends having a predetermined distance therebetween that together define the tube end spacing pattern of the brazed headerless core assembly;

centers between the tubes, substantially parallel to the tubes, and brazed to the planar surfaces of the tubes with a braze material; and

means for maintaining the predetermined distances and the tube end spacing pattern defined thereby, the maintaining means comprising the centers and excluding a plate or other structural member secured transverse to the tubes to maintain the predetermined distances and the tube end spacing pattern, whereby the tube ends are unrestricted and the predetermined distances and the tube end spacing pattern are exclusively determined by the centers; and wherein

the braze material has a melting temperature so as to be molten at about 600° C. and below melting temperatures of the tubes and centers;

the predetermined distances and the tube end spacing pattern enable the tube ends to be simultaneously received in and sealed with the resilient sealing means in the apertures in the header members of the pre-existing heat exchanger assembly; and

the tube ends are sized to be smaller than the apertures of the header members to accommodate the resilient sealing means therebetween.

2. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , wherein the core assembly consists of the tubes, the centers therebetween, the maintaining means, the braze material, and optionally internal fins within the tubes.

3. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , wherein the tubes are flat aluminum alloy tubes and the centers are sinusoidal aluminum alloy centers.

4. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , wherein the heat exchanger assembly is a charge air cooler and the core assembly is a modular component thereof.

5. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , wherein the braze material is an aluminum-based or zinc-based braze alloy.

6. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , further comprising means for enabling selective securement and removal of the brazed headerless core assembly with the head members using fasteners.

7. The brazed headerless core assembly and the pre-existing heat exchanger assembly according to claim 1 , further comprising supports apart from the brazed headerless core assembly and configured to be attached with fasteners to the header members of the pre-existing heat exchanger assembly and retain the tube ends of the brazed headerless core assembly within the apertures of the header members.