Abstract: An evaporator may be provided comprising a manifold, a plurality of micro-channel passageways, a distributor, and a separator. The manifold may comprise a shell defining a cavity. The plurality of micro-channel passageways may extend outwardly from the shell of the manifold, wherein the cavity may be in fluid communication with the plurality of micro-channel passageways. The distributor may comprise an inlet, an elongated body extending into the cavity of the manifold and defining a lumen, and a plurality of openings arranged on an outer surface of the elongated body and spaced along a length of the elongated body, wherein the openings may be configured to allow fluid communication between the lumen and the cavity of the manifold. The separator may be positioned between the plurality of openings within the cavity of the manifold.

Abstract: A heat exchanger assembly having a manifold, a partition member inserted into the interior cavity of the manifold through an open end such that the partition member cooperates with the interior surface of the manifold to partition the interior cavity into a manifold chamber and a distributor/collector chamber. The partition member and distributor/collector chamber function together as a distributor/collector tube within the manifold. The partition member includes a plurality of orifices along a length of the partition member, two opposite facing flange portions along the length of the partition member, a bulkhead panel extending from an end of the partition member adjacent the open end of the manifold, and a spring locator tab panel extending from an end of the partition member opposite of the bulk head panel, wherein the spring locator tab panel is biased against the closed end.

Abstract: A heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, and a plurality of refrigerant tubes in hydraulic communication with the first manifold and the second manifold. The second manifold includes a first end, a second end opposite from the first end, and a refrigerant inlet adjacent the first end. The plurality of refrigerant tubes includes tube ports. A portion of the tube ports are selectively obstructed such that a refrigerant entering into the second manifold through the refrigerant inlet flows substantially uniformly across the plurality of refrigerant tubes from the second manifold to the first manifold. At least one of the obstructed tube ports includes an inserted sliver of braze amendable material, pinched closed, or formed by inserting a pin of reduced diameter into the selected ports and then squeezing the port from the outside to size it and then removing the pin.

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: An evaporator may be provided comprising a manifold, a plurality of micro-channel passageways, a distributor, and a separator. The manifold may comprise a shell defining a cavity. The plurality of micro-channel passageways may extend outwardly from the shell of the manifold, wherein the cavity may be in fluid communication with the plurality of micro-channel passageways. The distributor may comprise an inlet, an elongated body extending into the cavity of the manifold and defining a lumen, and a plurality of openings arranged on an outer surface of the elongated body and spaced along a length of the elongated body, wherein the openings may be configured to allow fluid communication between the lumen and the cavity of the manifold. The separator may be positioned between the plurality of openings within the cavity of the manifold.

Abstract: A heat exchanger assembly having a first manifold, a second manifold spaced from the first manifold, and a plurality of refrigerant tubes in hydraulic communication with the first manifold and the second manifold. The second manifold includes a first end, a second end opposite from the first end, and a refrigerant inlet adjacent the first end. The plurality of refrigerant tubes includes tube ports. A portion of the tube ports are selectively obstructed such that a refrigerant entering into the second manifold through the refrigerant inlet flows substantially uniformly across the plurality of refrigerant tubes from the second manifold to the first manifold. At least one of the obstructed tube ports includes an inserted sliver of braze amendable material, pinched closed, or formed by inserting a pin of reduced diameter into the selected ports and then squeezing the port from the outside to size it and then removing the pin.

Abstract: The disclosure relates to a method of manufacturing a heat exchanger assembly with an enhanced material system. The enhanced material system includes refrigerant tubes extruded from a high purity AA3000 series alloy billet having about 1% by weight (wt %) Mn and pre-braze treated with either a reactive zinc flux or a mixture of elemental zinc powder and a controlled atmosphere brazed (CAB) flux applied by glass plasma or organic binder, such as an organic binder, fins formed from modified a AA3003 alloy having less than 0.05 wt % Cu and from 1.2 to 1.8% wt % Zn, and header manifolds manufactured from a AA3000 series alloy with a AA4000 series cladding having 0.9 to 1.1 wt % Zn. The enhanced material system may also include a post braze coating and a subsequent organic polymer resin topcoat.

Abstract: The disclosure relates to a method of manufacturing a heat exchanger assembly with an enhanced material system. The enhanced material system includes refrigerant tubes extruded from a high purity AA3000 series alloy billet having about 1% by weight (wt %) Mn and pre-braze treated with either a reactive zinc flux or a mixture of elemental zinc powder and a controlled atmosphere brazed (CAB) flux applied by glass plasma or organic binder, such as an organic binder, fins formed from modified a AA3003 alloy having less than 0.05 wt % Cu and from 1.2 to 1.8% wt % Zn, and header manifolds manufactured from a AA3000 series alloy with a AA4000 series cladding having 0.9 to 1.1 wt % Zn. The enhanced material system may also include a post braze coating and a subsequent organic polymer resin topcoat.

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 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 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: 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: 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.

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: A receiver-dehydrator assembly for use in an automobile air conditioning system is provided which incorporates a seamless, aluminum canister with universal-style inlet-to-outlet connector construction. The universal orientation feature consists of an octagonal perimeter at the top of the canister, which accommodates location of the outlet connector in relation to the inlet connector in any 45 degree radial increment. Mechanical joining processes are employed during the manufacturing of this assembly, so as to maximize the cleanliness and dimensional integrity of the assembly. The versatile, one piece canister design provides a clean, seamless, leak free integral assembly.

Abstract: An accumulator/dehydrator for a motor vehicle air conditioning system has a bleed valve that operates in parallel with a normal fixed area bleed hole to provide for increased lubricant flow to a compressor under low charge conditions.

Abstract: An accumulator-dehydrator assembly for an air conditioning system is provided with a desiccant canister outlet fitting having an integral particulate filter cage at one end an integral neck at an opposite end. The cage is insertable through and the neck is received in a flanged outlet opening in a desiccant canister that is received within the assembly's housing. The neck is also received from the interior of this housing in and sealingly engages with the housing's outlet connector. Both the neck and the flange about the canister outlet opening have radial holes which align and receive an exit end of the assembly's pickup tube arranged external of the canister. The neck and the canister outlet opening flange having cooperating angular alignment means that positively align their pickup tube accommodating holes angularly. The filter cage and the interior of the canister have cooperating longitudinal alignment means that positively align the pickup tube accommodating holes longitudinally.

Abstract: An accumulator-dehydrator assembly for an air conditioning system is provided with a desiccant canister outlet fitting having an integral particulate filter cage at one end and an integral neck at an opposite end. The cage is insertable through and the neck is received in a flanged outlet opening in a desiccant canister that is received within the assembly's housing. The neck is also received from the interior of this housing in and sealingly engages with the housing's outlet connector. Both the neck and the flange about the canister outlet opening have radial holes which align and receive an exit end of the assembly's pickup tube arranged external of the canister. The neck and the canister outlet opening flange have cooperating angular alignment means that positively align their pickup tube accommodating holes angularly. The filter cage and the interior of the canister have cooperating longitudinal alignment means that positively align the pickup tube accommodating holes longitudinally.