Abstract: A heat exchanger manifold (10) that comprises multiple members (20,22) and makes use of a simple snap-fit assembly technique to secure the members (2022) together. The manifold (10) includes first and second members (20,22), each of which comprises a rib (26) and first and second extensions (24) separated by the rib (26) and laterally extending from the rib (26). The extensions (24) of each member laterally terminate in edges (42) that abut the edges (42) of the other member. The ribs (26) of the members have complementary snap-fit means (28,30) for securing the first and second members (20,22) together. During assembly of the members (20,22), the snap-fit means (28,30) are aligned with each other and then engaged by applying a force on exterior surfaces of the manifold members (20,22), preferably opposite the ribs (26) to reduce the risk of damage to the extensions (24).

Abstract: Manifold for a heat exchanger intended to be joined by brazing or soldering to heat transfer tubes. A portion of a surface of the manifold that will be joined to the tubes is proved with at least one recess in which a brazing material is mechanically locked.

Abstract: A heat exchanger manifold (10) and method of forming a tube port (50) on the manifold (10). The manifold (10) comprises first and second walls (12,14) that define an internal passage (18) and an outer cross-sectional shape of the manifold (10). The first wall (12) of the manifold (10) has a concave outer surface in which the tube port (50) of the manifold (10) is to be formed, while the second wall (14) has a convex outer surface. The tube port (50) is formed in the concave first wall (12), such as by piercing. The shapes of the first and second walls (12,14) promote the ability of the manifold (10) to resist deformation when forming the tube port (50) in the first wall (12).

Abstract: A method for enhancing the brazeability of a heat exchanger manifold block (110) by promoting the braze metal flow in and around the manifold block (110) during brazing within a braze furnace. The invention is particularly directed to enhancing a brazement between a manifold block (110) and a jumper tube (124) that fluidically connects the block (110) to another component of the heat exchanger system. The method entails increasing the rate of convective and radiative heat transfer to the block (110) during brazing within a braze furnace by providing fins (116, 128), grooves (118, 130) or similar features on one or more surfaces of the block (110) that increase the surface area of the block (110), and consequently increase the heating rate of the block (110) to something closer to that of the tube (124). In effect, the surface features increase the heat transfer rate of the block (110) to compensate for the disparate thermal masses of the block (110) and tube (124).

Abstract: A consumable brazing encapsulate is used for joining aluminum to metal surfaces, e.g. aluminum, copper, brass or steel surfaces, by brazing. The encapsulate comprises a mixture of particles of an eutectic forming metal selected from the group consisting of silicon, germanium, copper and zinc and particles of a brazing flux encapsulated in a layer or layers of aluminum or its alloys, said eutectic forming metal and flux being present in the following parts by weight per 100 parts by weight of the total aluminum in the encapsulate: (a) 7 to 15 parts of silicon and 7 to 45 parts of flux; (b) 25 to 120 parts of germanium and 100 to 250 parts of flux; (c) 40 to 70 parts of copper and 20 to 100 parts of flux; (d) 1300 to 2400 parts of zinc and 1000 to 2000 parts of flux; such that when the encapsulate is placed between aluminum surfaces to be joined and is heated, the eutectic forming metal and the encapsulating aluminum are totally converted in situ into an eutectic filler metal for joining the aluminum surfaces.