Heat exchanger

A reinforced header assembly for use in a heat exchanger, the heat exchanger including a core including a plurality of tubes having opposite ends, and a plurality of fins extending between associated ones of the plurality of tubes, and a tank including a tank wall at least partially defining a cavity and having an end, the assembly comprising:

• a header connectable with the tank to define a collection tank assembly, the header including
• a central portion defining a plurality of header openings, each header opening being connectable to one opposite end of an associated tube such that the tube is in fluid communication with the collection tank assembly, and
• a connecting portion extending away from the central portion and connectable to the end of the tank wall such that the tank portion and the header cooperate to define the collection tank assembly, the connecting portion including a wall extending at a non-parallel angle relative to the central portion;
• and
• a reinforcement member including
• an inner portion defining a plurality of member openings, at least one of the plurality of tubes extending through each member opening to connect with the header, and
• an outer portion extending at a non-parallel angle relative to the inner portion, the outer portion being complementary to and connected to at least a portion of the wall of the connecting portion of the header.

A method of assembling a heat exchanger, the heat exchanger including a core including a plurality of tubes having opposite ends, and a plurality of fins extending between associated ones of the plurality of tubes, a first tank including a tank wall at least partially defining a cavity and having an end, a first header including a central portion defining a plurality of first header openings, and a connecting portion extending away from the central portion, the connecting portion including a wall extending at a non-parallel angle relative to the central portion, and a first reinforcement member including an inner portion defining a plurality of member openings, and an outer portion extending at a non-parallel angle relative to the inner portion, a second tank including a tank wall at least partially defining a cavity and having an end, a second header including a central portion defining a plurality of second header openings, and a connecting portion extending away from the central portion, the connecting portion including a wall extending at a non-parallel angle relative to the central portion, and a second reinforcement member including an inner portion defining a plurality of second member openings, and an outer portion extending at a non-parallel angle relative to the inner portion, the method comprising the acts of:

• connecting the outer portion of the first reinforcement member to at least a portion of the wall of the connecting portion of the first header, the outer portion of the first reinforcement member being complementary to the at least a portion of the wall of the connecting portion of the first header;
• connecting each first header opening to one opposite end of an associated tube, at least one of the plurality of tubes extending through each first member opening to connect with the first header;
• connecting the first header with the first tank to define a first collection tank assembly such that the plurality of tubes is in fluid communication with the first collection tank assembly;
• connecting the outer portion of the second reinforcement member to at least a portion of the wall of the connecting portion of the second header, the outer portion of the second reinforcement member being complementary to the at least a portion of the wall of the connecting portion of the second header;
• connecting each second header opening to another opposite end of an associated tube, at least one of the plurality of tubes extending through each second member opening to connect with the second header;
• and
• connecting the second header with the second tank to define a second collection tank assembly such that the plurality of tubes is in fluid communication with the second collection tank assembly.