Abstract: A method of fabricating a condenser tube having a pre-determined tube length and multiple channels including the steps of forming an aperture in a flat strip of metal; moving the flat strip through a plurality of forming operations to fold into an enclosed tube containing channels, which channels include the aperture in their sides and bottoms; and severing the enclosed tube across the aperture to separate the enclosed tube into one condenser tube. The aperture eliminates the need for the channel sides to be severed, hence only the portion of the condenser tube enclosing the channels requires severing. Each pair of apertures is spaced from the next pair of apertures by the pre-determined tube length so that each sever produces one condensing tube of the pre-determined tube length with the apertures being divided into open notches. The invention also includes a heat exchanger utilizing the condenser tube with channel sides containing portions of the apertures.

Abstract: A method of fabricating a condenser tube having a pre-determined tube length and multiple channels including the steps of forming an aperture in a flat strip of metal; moving the flat strip through a plurality of forming operations to fold into an enclosed tube containing channels, which channels include the aperture in their sides and bottoms; and severing the enclosed tube across the aperture to separate the enclosed tube into one condenser tube. The aperture eliminates the need for the channel sides to be severed, hence only the portion of the condenser tube enclosing the channels requires severing. Each pair of apertures is spaced from the next pair of apertures by the pre-determined tube length so that each sever produces one condensing tube of the pre-determined tube length with the apertures being divided into open notches. The invention also includes a heat exchanger utilizing the condenser tube with channel sides containing portions of the apertures.

Abstract: A secondary heat exchanger subassembly, such as a transmission oil cooler, is disposed in a metal tank of a radiator and has a pair of metal fluid fittings. Either a connector ring engages a fitting extending through the opening in the tank or a connector nut extends into the opening to threadedly engage the fitting whereby the metal fittings are held to the metal tank and inserted into a furnace for being brazed into sealed relationship with the metal tank.

Abstract: A heat exchanger is disclosed. A plurality of guides are integrally formed with the walls of a header tank and are used to position an oil cooler inside the tank to align a pair of fittings carried by the cooler with a pair of spaced openings in the tank.

Abstract: A metal tank cap is integral with a reinforcing member via a narrow connection and is flared outwardly at the narrow connection portion to be over an open end of the tank simultaneously with moving the metal tubes of the core into the tank. By unbending the connection portion, the respective tank caps are deflared into the open ends of the respective tanks and the entire assembly is placed in a furnace and brazed together.

Abstract: A one-piece header tank includes side edges that are overlapped and brazed together to form a joint positioned within the interior of the tank. The tank also includes an integrally formed mounting flange that may be fabricated without jeopardizing the leak integrity of the tank.

Abstract: An improved air center form roll for use in combination with a like form roll to produce an accordion-like folded fin for a heat exchanger core, the form roll being of the type comprising a plurality of form discs abutted one to the other and having a plurality of star-like teeth thereabout. Points of the star-like teeth define a major diameter of the form roll and valleys between adjacent ones of the star-like teeth define a minor diameter of the form roll. The form roll further includes at least one stripper disc having no teeth therearound and interposed between at least two of the plurality of form discs wherein the stripper disc has a diameter less than the minor diameter of the form roll. The improvement to the form roll comprises a modified disc having a plurality of modified star-like teeth thereabout. The modified disc is interposed at each abutment between the stripper disc and one of the abutting form discs.

Abstract: An improved air center form roll for use in combination with a like form roll to produce an accordion-like folded fin for a heat exchanger core, the form roll being of the type comprising a plurality of form discs abutted one to the other and having a plurality of star-like teeth thereabout. Points of the star-like teeth define a major diameter of the form roll and valleys between adjacent ones of the star-like teeth define a minor diameter of the form roll. The form roll further includes at least one stripper disc having no teeth therearound and interposed between at least two of the plurality of form discs wherein the stripper disc has a diameter less than the minor diameter of the form roll. The improvement to the form roll comprises a modified disc having a plurality of modified star-like teeth thereabout. The modified disc is interposed at each abutment between the stripper disc and one of the abutting form discs.