Abstract: A machine for bending a first set and a second set of folded deformable links projecting outwardly from a heat exchanger core made is disclosed. The machine comprises a base, a transport mechanism for transporting the core to a workstation, a locking mechanism for locking the core in a predetermined orientation in the workstation, and a bending mechanism attached to the base for bending a set of folded deformable links against the core.

Abstract: A method for transporting heat exchanger fins and forming a core subassembly for a heat exchanger uses a universal fin tray for all subassemblies instead of different tray sizes for different core subassemblies. The method includes indexing core plates forward under a stationary fin stuffing box, loading fins into the universal fin tray, indexing the loaded fins forward one at a time corresponding to the number of fins required, pushing required fins into the fin stuffing box when indexing reaches number required for the core subassembly, and pushing fins out of the fin stuffing box into the plates forming the core subassembly. A universal fin tray size, a stationary fin box, and a stationary cut off are used for all core sizes.

Abstract: A method for forming a heat exchanger is disclosed. The method includes the steps of forming a plurality of generally planar plate members from a sheet of material, each of the plate members being connected to an adjacent plate member by a deformable link. The method further includes forming a plurality of tube members by folding the plurality of plate members at the deformable links, inserting a fin member between adjacent tube members, and compressing the plurality of tube members and fin members under a predetermined load to form a heat exchanger core. The method also includes the steps of bending the folded deformable links against the core and brazing the core at a predetermined temperature. A heat exchanger manufactured according to this method is also disclosed.

Abstract: A heat exchanger formed from a plurality of adjacent, contiguous plate members is disclosed. The plate members are joined together by a first and second set of tabs, the tabs being configured to bend at predefined locations. The plates are folded in a bellows-like fashion to form a heat exchanger core. The bend zones provide proper plate-to-plate contact when forming the plate tubes as well as proper fin height spacing between adjacent pairs of plate tubes.

Abstract: A machine for corrugating preformed plates that form the core element of a heat exchanger. A fold forming mechanism imparts an initial fold in the deformable links joining a series of preformed plates received from an external source. A gathering mechanism gathers the folded series of preformed plates to produce a flow of pairs of mating plates. Precut lengths of corrugated fins are then inserted between joined adjacent pairs of mating plates and a cut-off mechanism severs the deformable links of preselected pairs of links joining pairs of mating plates to separate individual core elements from the flow of plates.

Abstract: An apparatus for selectively orienting consecutive fin strips relative to one another as a preliminary step in the manufacture of a heat exchanger includes a sensor for sensing the presence of each of a series of fin strips all having a common orientation relative to one another. The apparatus includes an orienting member which receives signals from the sensor as to the presence of each fin strip and rotates each consecutive fin strips in alternating clockwise and counter-clockwise directions to orient consecutive fin strips 180.degree. relative to each adjacent fin strip.