Abstract: A heat exchanger and method of making a heat exchanger which includes providing a header having openings adapted to receive a plurality of tubes. The tubes are inserted into the header openings, then, substantially uncured fluid sealing material is applied to at least the inner surfaces of the header openings. The inner surfaces of the header openings and the outer surfaces of the tubes are connected by the sealing material. The method further includes curing the sealing material after the tubes are inserted into the header openings. The sealing material thus provides a flexible, bonded, liquid tight, tube-to-header joint.

Abstract: A heat exchanger package for a motor vehicle includes a radiator and charge air cooler, each having a length between opposite ends and including front and rear opposite faces through which air flows. Each has an overlapping fluid-cooling portion at one end, wherein the rear face at one end of the radiator is disposed adjacent the front face at one end of the charge air cooler, such that the air flows sequentially in series through the overlapping portions of each. Each further has a non-overlapping fluid-cooling portion at the opposite end wherein the rear face at the opposite end of the radiator extends outward of the charge air cooler and the front face at the opposite end of the charge air cooler extends outward of the radiator, such that the air flows singularly and in parallel through each of the non-overlapping portions.

Abstract: A heat exchanger package for a motor vehicle comprises a radiator and charge air cooler, each having a length between opposite ends and including front and rear opposite faces through which air flows. Each includes an overlapping fluid-cooling portion at one end, wherein the rear face at one end of the radiator is disposed adjacent the front face at one end of the charge air cooler, such that the air flows sequentially in series through the overlapping portions of each. Each further has a non-overlapping fluid-cooling portion at the opposite end wherein the rear face at the opposite end of the radiator extends outward of the charge air cooler and the front face at the opposite end of the charge air cooler extends outward of the radiator, such that the air flows singularly and in parallel through each of the non-overlapping portions.

Abstract: A heat exchanger and method of making a heat exchanger which includes providing a header having openings adapted to receive a plurality of tubes. The tubes are inserted into the header openings, then, substantially uncured fluid sealing material is applied to at least the inner surfaces of the header openings. The inner surfaces of the header openings and the outer surfaces of the tubes are connected by the sealing material. The method further includes curing the sealing material after the tubes are inserted into the header openings. The sealing material thus provides a flexible, bonded, liquid tight, tube-to-header joint.

Abstract: A heat exchanger and method of making a heat exchanger which includes providing a header having openings adapted to receive a plurality of tubes. The tubes are inserted into the header openings, then, substantially uncured fluid sealing material is applied to at least the inner surfaces of the header openings. The inner surfaces of the header openings and the outer surfaces of the tubes are connected by the sealing material. The method further includes curing the sealing material after the tubes are inserted into the header openings. The sealing material thus provides a flexible, bonded, liquid tight, tube-to-header joint.

Abstract: A heat exchanger comprising a core assembly having a plurality of tubes connected by an array of fins, with ends of the tubes extending from the fin array on at least one side of the core assembly and resilient, polymeric grommets disposed around, the tube ends. The heat exchanger includes a tank portion for receiving fluid entering or leaving the core assembly and a header portion having openings to receive the tube ends and grommets to create a sealed, fluid-tight tube-to-header joint. There is provided a reinforcing member across the opening of the tube ends extending from the tube end opening to the portion of the tube end around which the grommet is disposed without substantially extending into the fin array portion of the core assembly. The header portion comprises a substantially planar base having openings therein with side and end walls extending out of the plane of the base and connected by one or more fluid-tight welds to the tank portion.

Abstract: A heat exchanger comprises an as-cast combined header and tank having a header portion integral with a tank portion. The cast header and tank combination has a plurality of openings originally cast in the header portion of the combination and at least one opening originally cast in the tank portion of the combination for passage of coolant into or out of the cast header and tank combination. Tubes are received in and extends through the header portion openings, and resilient grommets seal the tubes to the header portion to prevent leakage around the tubes. In making the heat exchanger, there is provided an inner mold section and outer mold section corresponding respectively to the interior and exterior configurations of a desired combined header and tank having a header portion integral with a tank portion.

Abstract: A heat exchanger comprising a core assembly having a plurality of tubes connected by an array of fins, with ends of the tubes extending from the fin array on at least one side of the core assembly and resilient, polymeric grommets disposed around the tube ends. The heat exchanger includes a tank portion for receiving fluid entering or leaving the core assembly and a header portion having openings to receive the tube ends and grommets to create a sealed, fluid-tight tube-to-header joint. There is provided a reinforcing member across the opening of the tube ends extending from the tube end opening to the portion of the tube end around which the grommet is disposed without substantially extending into the fin array portion of the core assembly. The header portion comprises a substantially planar base having openings therein with side and end walls extending out of the plane of the base and connected by one or more fluid-tight welds to the tank portion.

Abstract: A method of manufacturing a heat exchanger comprising a core assembly having a plurality of tubes connected by an array of fins, with ends of the tubes extending from the fin array on at least one side of the core assembly and resilient, polymeric grommets disposed around the tube ends. The heat exchanger includes a tank portion for receiving fluid entering or leaving the core assembly and a header portion having openings to receive the tube ends and grommets to create a sealed, fluid-tight tube-to-header joint. There is provided a reinforcing member across the opening of the tube ends extending from the tube end opening to the portion of the tube end around which the grommet is disposed without substantially extending into the fin array portion of the core assembly. The header portion comprises a substantially planar base having openings therein with side and end walls extending out of the plane of the base and connected by one or more fluid-tight welds to the tank portion.

Abstract: A heat exchanger comprises an as-cast combined header and tank having a header portion integral with a tank portion. The cast header and tank combination has a plurality of openings originally cast in the header portion of the combination and at least one opening originally cast in the tank portion of the combination for passage of coolant into or out of the cast header and tank combination. Tubes are received in and extends through the header portion openings, and resilient grommets seal the tubes to the header portion to prevent leakage around the tubes. In making the heat exchanger, there is provided an inner mold section and outer mold section corresponding respectively to the interior and exterior configurations of a desired combined header and tank having a header portion integral with a tank portion.