Abstract: A method for making a heat exchanger assembly (10) includes inserting tubes (20) through fin holes (32) in heat exchanger fins (30) and headers (40, 42) to form a bundle (50), and expanding the tubes (20) forming an interference fit with the heat exchanger fins (30). The bundle (50) is inserted into a housing (60) open at both end; (67, 68) and having a wall (62) surrounding the headers (40, 42) with inlet and outlet lines (64, 66) in the wall (62), and sealing the wall (62) of the housing (60) to the first and second headers (40, 42) with the inlet and outlet lines (64, 66) disposed between the headers (40, 42). A plurality of mandrel heads (70) are inserted through the open ends (67, 68) of the housing (60) into the tubes (20) expanding the tubes (20) into the headers (40, 42) to form a sealed joint between the tubes (20) and the headers (40, 42).

Abstract: A heat exchanger assembly (10) includes a pair of tanks (16, 18) with a plurality of flat-sided fluid tubes (20) extending between the tanks (16, 18). Fins (22) may be located externally between adjacent fluid tubes (20), and may be located internally within each fluid tube (20) for increasing heat exchange. The fins (22) are formed by a plurality of undulations (32) establishing lengths of walls (34) between peaks (36) of the undulations (32). The walls (34) include a plurality of slits (44) therein forming panels (42) between adjacent slits (44). The panels (42) are "randomly" deformed of various contours to extend at various distances from the walls (34) to increase heat exchange.

Abstract: A heat exchanger (10) is comprised of a pair of manifolds (12, 14) with a heat exchanger core (20) therebetween, and an upper side support (22) and a lower side support (44) along the outer sides of the core (20) connected between the manifolds (12, 14). The upper side support (22) includes mounting brackets (40). The lower side support (44) comprises the mounting bracket. A pair of loading members (52) are connected between the lower mounting bracket (44) and the manifolds (12, 14) in angular relationship thereto to allow additional support and loading through the manifolds (12, 14), and to allow thermal expansion of the exchanger (10) with minimal restriction.

Abstract: A heat exchanger (10) includes a pair of manifolds (12, 14) interconnected by a core member having a plurality of fluid tubes (20) extending between manifolds (12, 14) and fins (22) connected between adjacent fluid tubes (20). The fin (22) is comprised of a corrugated sheet of material forming peaks connected to the tubes (20) with fin walls (34) extending between peaks. Alternating walls (34) of the fin (22) are comprised of an uninterrupted section (40) and a louvered section (42). The uninterrupted section (40) is defined by either a sinusoidal wave of continuous sheet or straight section deformed into the wall (34). The louvered section (42) is defined by a plurality of louvers (46) interrupting and cut into the sheet formed in the wall (34) providing air gaps.

Abstract: A heat exchanger assembly (10) includes a pair of manifolds (12, 14) with a core member (20) connected therebetween. The core member (20) includes a plurality of fluid tubes (16) extending between the manifolds (12, 14) in fluid communication therewith, a plurality of air fins (18) connected between the fluid tubes (16), and a pair of side support members (22) are joined to the manifolds (12, 14) at the outermost sides thereof. Reinforcement straps (50) are connected at each corner of the assembly (10) between the side support members (22) and the manifolds (12, 14) to reinforce the joints of the assembly (10).