Abstract: A tube-to-header sealing system for a heat exchanger comprises a pair of mating header plates, each header plate having a wall with a plurality of openings therein and including a continuous depression along the circumference of each header plate opening which forms one-half of an O-ring groove. Each of a plurality of O-rings is positioned in each O-ring groove and the header plates are secured together such that the header plate plurality of openings are aligned and trap each of the plurality of O-rings in O-ring grooves. A plurality of spaced-apart tubes each having a tube end secured in an opening in the wall of the header to form a tube-to-header joint are expanded outwardly to provide sufficient O-ring deformation to obtain a seal. In service, the resiliency of the O-ring seal allows for expansion and contraction of the tubes without the build-up of high stresses at the tube-to-header joint.

Abstract: A helical heat exchanger assembly comprises a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter, and a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis. The tube insert is sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube, respectively. A plurality of inlet and outlet fluid ports are positioned for passage of a first and second fluid into and out of the tube.

Abstract: A helical heat exchanger assembly comprises a plurality of helical heat exchangers, each helical heat exchanger comprising a tube having first and second ends, a length, an inner diameter and a cross-section incorporating the inner diameter, a thermally conductive tube insert having a length and an outer diameter substantially equal to the inner diameter of the tube, the tube insert having first and second ends and comprising a single helix extending along the length of the tube insert and twisted around a central axis. The tube insert is sealed within the tube by sealing an outer edge of the helix to an inner surface of the tube to form fluid-tight first and second fluid flow paths defined between opposing sides of the helix and the inner surface of the tube, respectively. A plurality of inlet and outlet fluid ports are positioned for passage of a first and second fluid into and out of each tube.

Abstract: A modular heat exchanger assembly for ultra-large radiator applications. At least two heat exchanger cores are arranged in parallel flow, each core including inlet and outlet tanks sealingly attached to opposing headers at each end of a plurality of tubes. Each header is formed by securing mating header plates having mating openings. A plurality of O-rings are trapped within O-ring grooves formed by continuous depressions around each of the mating openings, and a portion of each tube is disposed within one of the O-rings and expanded outwardly to form a seal at each tube-to-header joint. A common tank is connected between tanks at adjacent ends of each heat exchanger core, and separate tanks are connected to the tank at the opposing ends of each core. The separate tanks may be inlet tanks and the common tank may be an outlet tank for fluid, or the flow path may be reversed.

Abstract: A header for a heat exchanger manifold comprises a header plate with a periphery, a plurality of tube openings within the header plate periphery adapted to connect to tubes of a heat exchanger core, a groove around the periphery of the header plate to receive a foot of a tank, the groove comprising inner and outer vertical walls and a lower wall disposed therebetween, and a header groove reinforcement member secured to and extending along an outer surface of the header groove and along at least a portion of the length of the header plate in a direction transverse to the header groove. The header groove reinforcement member comprises a first portion extending along at least a portion of a length of the outer vertical wall in the direction of a distal end, and a second portion extending past a proximal end of the inner vertical wall and along at least a portion of the length of the header plate.

Abstract: A tube-to-header sealing system for a heat exchanger comprises a pair of mating header plates, each header plate having a wall with a plurality of openings therein and including a continuous depression along the circumference of each header plate opening which forms one-half of an O-ring groove. Each of a plurality of O-rings is positioned in each O-ring groove and the header plates are secured together such that the header plate plurality of openings are aligned and trap each of the plurality of O-rings in O-ring grooves. A plurality of spaced-apart tubes each having a tube end secured in an opening in the wall of the header to form a tube-to-header joint are expanded outwardly to provide sufficient O-ring deformation to obtain a seal. In service, the resiliency of the O-ring seal allows for expansion and contraction of the tubes without the build-up of high stresses at the tube-to-header joint.

Abstract: A heat exchanger tube has a tube end having two extended portions substantially opposite the other around the periphery of the tube end, and two shortened portions, each positioned between the two extended portions and substantially opposite the other around the periphery of the tube end. The tube end may be formed by removing opposite portions of the tube by cutting a disc-shaped portion with a generally smoothly curving periphery along a major portion of the width of the tube. Each tube is oriented within an opening in the header wall of a heat exchanger assembly having a header portion integral with a tank portion, such that the tube end two extended portions are oriented substantially perpendicular to the direction of fluid flow within the header and the tube end two shorter portions are oriented substantially in the direction of fluid flow in order to reduce interference with fluid flow.

Abstract: A heat exchanger manifold comprises a heat exchanger header having a header plate with a periphery, a plurality of tube openings within the header plate portion periphery adapted to connect to tubes of a heat exchanger core, a groove around the periphery of the header plate to receive a foot of a tank, and a fastener base extending inward from the header plate. The manifold includes a heat exchanger tank having an opening for mating with the header, a foot extending substantially around a periphery of the opening which is received in the header groove, and a fastener base extending from an inner surface of the tank. A resilient sealing gasket is positioned between the tank foot and the header groove to seal the tank to the header, and a plurality of tabs extending around the periphery of the header are crimped over the tank foot to make the seal between the header groove and the tank foot.