Abstract: The disclosure presents a heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes extending between and in hydraulic communication with the first and second manifolds, a plurality of corrugated fins inserted between the plurality of refrigerant tubes, and a condensate extractor having a comb baffle portion with fingers inserted between the plurality of refrigerant tubes and a conveyance portion. The comb baffle portion is configured to extract condensate from between the plurality of refrigerant tubes and the conveyance portion is configured to convey condensate away from the heat exchanger assembly.

Abstract: A heat exchanger assembly having an insertable distributor tube retainer tab configured to position and retain a distributor tube disposed within a first manifold extending along an axis Amanifold. The first manifold includes a manifold wall having an interior surface defining an interior chamber, an exterior surface opposite of the interior surface, and a retainer slot connecting the interior surface and the exterior surface. The retainer slot extends substantially transverse to the manifold axis Amanifold. The retainer tab is inserted through the retainer slot and includes a first tab portion disposed within the interior chamber and a second tab portion 104 engaged to the wall of the first manifold, and may also include a third tab portion engaged to a width surface of the retainer slot. The retainer tab includes a tab opening configured to engage and maintain the distributor tube within the predetermined position.

Abstract: An improved corner bending apparatus and method for a bent head exchanger includes a first step of providing a tube edge clearance to at least the inner core face edges of those few tubes encompassed by the area of the core to be bent. A series of elongated braces, able to flex relative to one another, is placed into the tube edge clearance prior to bending. The braces actively maintain the tube edges (and tubes) in a parallel, undeformed orientation during the bend, which may be done by otherwise conventional apparatus.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: The disclosure presents a heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, a plurality of refrigerant tubes extending between and in hydraulic communication with the first and second manifolds, a plurality of corrugated fins inserted between the plurality of refrigerant tubes, and a condensate extractor having a comb baffle portion with fingers inserted between the plurality of refrigerant tubes and a conveyance portion. The comb baffle portion is configured to extract condensate from between the plurality of refrigerant tubes and the conveyance portion is configured to convey condensate away from the heat exchanger assembly.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: A heat exchanger assembly that includes an outlet header/manifold defining an outlet cavity, an outlet tube in fluidic communication with the outlet cavity, and a heat exchanger core. The outlet tube and the outlet cavity cooperate to reduce a temperature value range across the heat exchanger core by equalizing refrigerant distribution between the refrigerant tubes within the heat exchanger core. The length of the heat exchanger headers/manifolds may be increased for a predetermined packaging width because the outlet tube and inlet conduit may exit the headers/manifolds perpendicularly rather than axially, allowing the heat exchanger core width to be increased. The increased heat exchanger core width allows additional refrigerant tubes to be included in the heat exchanger core, providing decreased air pressure difference for air flowing through the heat exchanger assembly and increased heat capacity of the heat exchanger assembly.

Abstract: A heat exchanger assembly that includes an outlet header/manifold defining an outlet cavity, an outlet tube in fluidic communication with the outlet cavity, and a heat exchanger core. The outlet tube and the outlet cavity cooperate to reduce a temperature value range across the heat exchanger core by equalizing refrigerant distribution between the refrigerant tubes within the heat exchanger core. The length of the heat exchanger headers/manifolds may be increased for a predetermined packaging width because the outlet tube and inlet conduit may exit the headers/manifolds perpendicularly rather than axially, allowing the heat exchanger core width to be increased. The increased heat exchanger core width allows additional refrigerant tubes to be included in the heat exchanger core, providing decreased air pressure difference for air flowing through the heat exchanger assembly and increased heat capacity of the heat exchanger assembly.

Abstract: An improved corner bending apparatus and method for a bent head exchanger includes a first step of providing a tube edge clearance to at least the inner core face edges of those few tubes encompassed by the area of the core to be bent. A series of elongated braces, able to flex relative to one another, is placed into the tube edge clearance prior to bending. The braces actively maintain the tube edges (and tubes) in a parallel, undeformed orientation during the bend, which may be done by otherwise conventional apparatus.

Abstract: An improved heat exchanger assembly having an inlet header in hydraulic communication with an outlet header via a plurality of multi-channel flat refrigerant tubes, in which the multi-channel flat refrigerant tubes are substantially perpendicular to the headers. Interconnecting the refrigerant tubes are corrugated fins. The plurality of refrigerant tubes together with the fins defines the core of the heat exchanger assembly. The heat exchanger assembly also includes a distributor tube disposed in the inlet header cavity and a collector tube disposed in the outlet header cavity. The distributor tube and collector tube have cooperating features for archiving uniform refrigerant distribution through the refrigerant tubes.

Abstract: An improved bending apparatus for bending a radiused corner at a window in a brazed heat exchanger core where no tubes and fins are located. A cylindrical mandrel and sliding pressure die are designed to completely surround the manifold in the areas of the window and provide a continuous, rolling contact area or profile support around the manifold as the bending moment is applied.

Abstract: A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Abstract: A heat exchanger assembly includes an outlet header extending along an outlet axis to define an outlet cavity and an inlet header defining an inlet cavity. A plurality of refrigerant tubes extends from the inlet header through the outlet header and into the outlet cavity. A collector conduit having a generally semi-circular conduit cross-section defining an arced surface and a chord surface interconnected with rounded ends is disposed in the outlet header and includes a conduit body portion and at least one conduit end portion interconnected by a conduit transition portion with the conduit body portion being offset from the conduit end portion. The conduit body portion is engaged to an interior surface of the outlet header to space the conduit body portion from the refrigerant tubes and the conduit end portion is coaxial with the outlet header axis to provide a central outlet for the refrigerant vapor.

Abstract: An core unit for a heat exchanger being bent about an axis perpendicular to the core unit's headers. Tubes establish fluid communication between the core unit's headers, and a bend relief spacer is disposed between first and second groups of tubes. During the bending process, the bend relief spacer facilitates the bend and ultimately maintains the performance of the core unit.

Abstract: A method for fabricating a heat exchanger assembly (20) includes pressing a pair of headers (30, 38) into refrigerant tubes (76). A notch (50) is cut axially into header ends (32, 40). An inner radial abutment (24) is formed in each of the refrigerant conduits (22, 56), which are then each inserted through an open end cap (26). An outer radial abutment (28) is formed in each of the refrigerant conduits (22, 56) so that the open end caps (26) are retained in position between the radial abutments (24, 28). The radial abutments (24, 28) can comprise a bead, a radially inwardly extending shoulder, an outwardly extending shoulder, or an expansion beneath the open end caps (26). A tool presses each subassembly into the corresponding headers (30, 38) until the tool reaches the corresponding notch bottom (52).

Abstract: A mini-channel heat exchanger or a micro-channel heat exchanger includes an insert (140, 240, 340, 440, 540, 640, 4, 940, 1040) having a volume. The insert is within a gap between a plurality of tubes (130, 230, 330, 430, 530, 630, 1, 930, 1030) of the mini-channel heat exchanger or the micro-channel heat exchanger and a manifold inner wall of a manifold (120, 220, 320, 420, 520, 620, 2, 920, 1020).

Abstract: A heat exchanger assembly includes an outlet header extending along an outlet axis to define an outlet cavity and an inlet header defining an inlet cavity. A plurality of refrigerant tubes extends from the inlet header through the outlet header and into the outlet cavity. A collector conduit is disposed in the outlet header and includes a conduit body portion and at least one conduit end portion interconnected by a conduit transition portion with the conduit body portion being offset from the conduit end portion. The conduit body portion is engaged to an interior surface of the outlet header to space the conduit body portion from the refrigerant tubes extending into the outlet header and the conduit end portion is coaxial with the outlet header axis to provide a central outlet for the refrigerant vapor.