Abstract: A core unit for a heat exchanger comprises a pair of headers spaced from one another each defining a fluid space for receiving a fluid therein and each defining a plurality of apertures. A first region comprising a plurality of first tubes extends between the headers and a first fin is disposed between adjacent pairs of the first tubes. A second region comprising a plurality of second tubes extends between the headers and a second fin is disposed between adjacent pairs of the second tubes. A crushable center different than the first and second regions is disposed parallelly between the first and second regions for controllably crushing when the headers are bent.

Abstract: A heat exchanger assembly includes a core having first and second header tanks covered by tank caps. A pair of core reinforcing members presenting terminal ends extend between the first and second header tanks. A least one tab and an opening for receiving the tab are used for connecting the core reinforcing members to the tank caps.

Abstract: A method of manufacturing a manifold of a heat exchanger is provided. The manifold has an outer wall and an inner tube with a cavity formed there between. The method utilizes a punch having a first cusp and a second cusp and includes the step of lancing the outer wall of the manifold utilizing both the first and second cusps to form a first aperture in the outer wall and to dispose the first and second cusps in the cavity. The method also includes the steps of moving the first and second cusps through the cavity toward the inner tube while maintaining at least one of the first and second cusps within the cavity and lancing the inner tube of the manifold utilizing the second cusp to form a second aperture in the inner tube. The method still further includes the step of retracting the punch from the manifold.

Abstract: A heat exchanger assembly has a first manifold, a second manifold in spaced and substantially parallel relationship with the first manifold and a plurality of flow tubes fluidly connecting the manifolds for passing refrigerant between the manifolds. The first manifold includes a header and tank which are joined by their longitudinal edges to form a cavity. The tank is extruded and has an outer wall and an inner partition wall with a plurality of apertures which define a distribution chamber within the cavity. The distribution chamber is fluidly connected to the cavity. A method of manufacturing a manifold generally includes the steps of extruding the tank, cutting the tank to a predetermined length, forming a plurality of apertures in the inner partition wall, forming a plurality of openings in the header, joining the tank and the header, and joining the end cap to the tank and header.

Abstract: A heat exchanger assembly includes a first manifold having a first manifold body with an outer wall defining a cavity and an inner partition wall integrally formed with the outer wall to define a distribution chamber disposed within the cavity. A second manifold defines a hollow cavity and is in spaced and substantially parallel relationship with the first manifold. A plurality of flow tubes extend between and fluidly connect the cavities of the manifolds. The inner partition wall has a plurality of apertures fluidly connecting the distribution chamber with the cavity. A method of manufacturing the first manifold includes the steps of extruding the manifold body, forming a plurality of openings in the outer wall, forming a plurality of apertures in the inner partition wall, inserting a separator in the manifold body, and mounting the end cap to one end of the first manifold body.

Abstract: The subject invention provides a heat exchanger assembly including a tank having a wall defining an aperture with a fitting secured thereto and a method of securing the fitting thereto. The fitting has a first end with an outer perimeter disposed exteriorly thereof and smaller than the aperture for inserting the first end of the fitting into the aperture. The fitting also has an internal tunnel extending along an axis thereto from the first end. A step of material is disposed in the tunnel at the first end, which is at least in part, radially and longitudinally displaced relative to the axis into contact with the wall to prevent rotational movement of the fitting in the aperture.

Abstract: A condenser for an air conditioning system includes a core assembly having a header tank and a receiver/dehydrator member operably connected to the core assembly for condensing a refrigerant flowing internally. The receiver/dehydrator or receiver member includes two openings to receive male couplers extending from a tubular member connected to the core assembly. The condenser includes a coupler that extends into the receiver/dehydrator member between each opening and the male couplers to form a seal therebetween. The coupler and the male coupler are connected one with the other by brazing. In an alternative embodiment, the male coupler includes a snap-in element to engage the male coupler with the coupler.

Abstract: A condenser that is to be brazed in a radiant energy oven has a significant, localized mass differential which would, without further treatment, create a significant temperature differential across the condenser in the braze oven. This is compensated for, in the method of the invention, by thermally spraying onto the surface of the higher mass portion a rough surface layer of a compatible material that increases the emissivity of that portion sufficiently, relative to the rest of the condenser, to decrease the temperature differential that would otherwise occur.