Snap-on bracket for a condenser header

A heat exchanger comprising in combination:

• two spaced apart header tubes, each being of two curved portions joined together at seams which define ribs on opposite edges, the ribs having tabs which are spaced apart along the edges of the header tubes;
• the ribs have a plurality of tabs spaced apart along the edges of the header tubes;
• a plurality of parallel tubes extending between the header tubes for passing refrigerant between the header tubes;
• external components for mounting to the header tubes;
• a central body portion having a concave contact surface for fitting flush against one of the curved portions of one of the header tubes;
• fastening means for securing one of the external components to the central body portion;
• a pair of arms extending from the central body portion, spaced apart for fitting around the ribs of the one of the header tubes, and each of the arms extending symmetrically about a central axis with respect to the other of the arms and being formed by extrusion;
• tips formed into the ends of the arms to extend substantially parallel to the central axis and the contact surface of the central body portion;
• the tips having tapered leading edges disposed equal distances from the central axis on sides of the tips which engage the one of the headers when placing the arms on opposite edges of the one of the headers, the leading edges extending parallel to the central axis and tapering toward the other of the arms in a direction toward the central body portion;
• the arms having side surfaces which face the other of the arms and extend symmetrically about the central axis to the other of the arms, and continuous shoulders with flat inner walls which extend between the side surfaces and the tips of the arms and face generally toward the central body portion;
• the arms have notches formed into the tips for receiving the tabs on the ribs to locate the central body portion relative to the one of the header tubes;
• and
• wherein the shoulders are spaced apart from the concave contact surface of the central body portion for engaging the ribs of the one of the header tubes for holding the central body portion against the one of the header tubes, with the concave contact surface fitting flush against the curved portion and the central axis extending parallel to a longitudinal axis of the one of the header tubes.

A method for fabricating a heat exchanger of the type having two spaced apart header tubes, a plurality of parallel tubes extending between the header tubes for passing refrigerant between the header tubes, and further having external components secured to the header tubes, the header tubes being of two curved portions joined together at seams which define ribs on opposite edges of the header tubes, the method comprising the steps of:

• providing a snap-on bracket having a central body portion with a concave surface for fitting flush against one of the header tubes, a pair of spaced apart arms extending from the central body portion symmetrically about a central axis with respect to the other of the arms, and continuous shoulders with flat inner walls formed into the ends of the arms to extend substantially parallel to the central axis and the concave surface of the central body portion;
• fitting end tips of the arms against the ribs of the one of the header tubes, with the central axis align parallel to a longitudinal axis of the one of the header tubes;
• pressing forward with substantially straight axial movement along a centerline which is equidistance between each of the tips and which intersects both the central axis of the snap-on bracket and the longitudinal axis of the one of the header tubes;
• pressing the tips over the ribs and catching the continuous shoulders against the ribs on opposite edges of the one of the header tubes, with the concave surface of the central body portion fitting flush against the one of the header tubes;
• then,
• passing the heat exchanger through a brazing furnace, brazing the snap-on bracket to the one of the header tubes;
• and
• fastening one of the external components to the central body portion to secure the one of the external components to the one of the headers.