Abstract: A multi-pass heat exchanger having a return manifold with a partition, a front wall, and a rear wall is provided. The partition separates the return manifold into a collection chamber and a distribution chamber. The front and rear walls define a fluid channel. The front wall has a plurality of perforations placing the fluid channel in separate fluid communication with the collection chamber and the distribution chamber.

Abstract: A multi-pass heat exchanger having a return manifold with a partition, a front wall, and a rear wall is provided. The partition separates the return manifold into a collection chamber and a distribution chamber. The front and rear walls define a fluid channel. The front wall has a plurality of perforations placing the fluid channel in separate fluid communication with the collection chamber and the distribution chamber.

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: An expansion device for a heat exchanger having a manifold and a plurality of mini- and or micro-channels. The expansion device has an outer element having a plurality of orifices therethrough that is received in the manifold, and an inner element telescopically received in the outer element having at least one orifice therethrough and being in fluid communication with the plurality of orifices. Fluid passing through the at least one orifice and through the plurality of orifices is expanded and reduced in pressure prior to entering the manifold.

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 joint between a pipe and a header wall defines an endless transition for conveying the heat exchange medium closely over a control surface of a radius or a chamfer between the interior surface and the pipe to reduce turbulence and pressure loss. The radiused or chamfered flow control surface expands radially as it opens axially into the interior surface of the header wall.