Abstract: A heat exchanger and a method of manufacturing a heat exchanger are described and shown. In some embodiments, the heat exchanger has a brazed core with flat metal tubes and flat metal tube ends received in corresponding openings defined in a collecting tank, and has a plurality of adhesive connections each with an annular space around a flat tube end and defined at least in part by the collecting tank, an addition-crosslinking silicone adhesive located within the annular space, and a mounting plate at least partially closing each annular space.

Abstract: A number of flat tubes, flat tube heat exchangers, and methods of manufacturing both are described and illustrated. The flat tubes can be constructed of one, two, or more pieces of sheet material. A profiled insert integral with the flat tube or constructed from another sheet of material can be used to define multiple flow channels through the flat tube. The flat tubes can be constructed of relatively thin material, and can be reinforced with folds of the flat tube material and/or of an insert in areas subject to higher pressure and thermal stresses. Also, the relatively thin flat tube material can have a corrosion layer enabling the material to resist failure due to corrosion. Heat exchangers having such flat tubes connected to collection tubes are also disclosed, as are manners in which such tubes can be provided with fins.

Abstract: A process for producing tubes (1), in particular for use in heat exchangers, from at least one metallic strip on a rolling mill train, wherein the strip, on a rolling mill train, is provided with predetermined breaking points, deformed and brought together to form the tube and finally the tubes are torn off at the predetermined breaking points between two pairs of rolls having a speed difference. The process is improved, in terms of the tearing off of individual tubes, in that an areal compressive force (Ak) is applied to the tube at least at the moment of tearing off and a sufficient tearing force (Rk) is produced and transmitted to the tube to be torn off.

Abstract: The invention relates to a heat exchanger, such as, for example, a liquid cooler, charge air cooler or the like, having two-part collecting tanks which are composed entirely of plastic and have inlet or outlet connecting pipes. One collecting tank part can have openings for receiving the ends of tubes, with the tube ends being adhesively connected therein, and with the two collecting tank parts being welded to one another at a weld seam which runs around the periphery of their walls. The two tank parts form an oval to round collecting tank cross section between the tubes, and the weld seam is situated in a seam preparation which is formed as a thickened portion of the walls of the tank parts. As a result of the invention, the heat exchanger is of particularly pressure-resistant design and is very production-friendly.

Abstract: The invention provides for a manufacturing process of a heat exchanger having a flat tube and fin core. The flat tube and fin core is formed in such a way that free flat tube ends are provided, wherein the flat tube and fin core is brazed in a brazing furnace, and wherein the flat tube ends are received in receptacle openings of a mounting plate and a header forming an enclosed space for receiving a bonding agent for coupling the flat tube ends to the header and mounting plate.

Abstract: A flat heat exchanger tube formed of a single strip of rolled aluminum, with at least one connection between the two broad sides. The connection is generally parallel to and spaced between the narrow sides and divides the heat exchanger tube into at least two chambers, and includes two legs consisting of bent opposite edges of the aluminum strip, the legs each having a head at adjacent bends along one of the broad sides and feet adjacent the other broad side. The legs lie against each other generally at their head over no more than half of the entire spacing between the two broad sides, with the legs enclosing an angle between them of about 20° to 100° or about 45° to 75°, advantageously 60°.

Abstract: A number of flat tubes, flat tube heat exchangers, and methods of manufacturing both are described and illustrated. The flat tubes can be constructed of one, two, or more pieces of sheet material. A profiled insert integral with the flat tube or constructed from another sheet of material can be used to define multiple flow channels through the flat tube. The flat tubes can be constructed of relatively thin material, and can be reinforced with folds of the flat tube material and/or of an insert in areas subject to higher pressure and thermal stresses. Also, the relatively thin flat tube material can have a corrosion layer enabling the material to resist failure due to corrosion. Heat exchangers having such flat tubes connected to collection tubes are also disclosed, as are manners in which such tubes can be provided with fins.

Abstract: A heat exchanger including a collecting tank having an outwardly extending flange around an edge, a tube plate having a connection edge, tubes having ends extending into openings in the tube plate, and an intermediate plate having an edge lying against the connection edge of the tube plate. The connection edges of the intermediate plate and the tube plate are both mechanically connected to the flange of the collecting tank. Pins in the corners of one of the tube plate and the intermediate plate secure the tube plate and intermediate plate together. The connection edge of the plates include protrusions bendable onto the edge flange of the collecting tank.

Abstract: An insert adapted to connect to opposite walls in a heat exchanger tube, including a corrugated sheet having alternating wave crests and wave troughs connected by wave flanks having openings therein, wherein at least some of the wave crests have a length different than the length of the wave troughs, and/or adjacent sections have different wavelength waves. Such inserts may be produced by transporting material sheets through a press, where the sheet feed rate and/or the press stroke speed may be selectively varied.

Abstract: A heat exchanger including a collecting tank having an outwardly extending flange around an edge, a tube plate having a connection edge, tubes having ends extending into openings in the tube plate, and an intermediate plate having an edge lying against the connection edge of the tube plate. The connection edges of the intermediate plate and the tube plate are both mechanically connected to the flange of the collecting tank. Pins in the corners of one of the tube plate and the intermediate plate secure the tube plate and intermediate plate together. The connection edge of the plates include protrusions bendable onto the edge flange of the collecting tank.

Abstract: A housing-less plate heat exchanger is provided for transferring heat between at least a first fluid and a second fluid. The heat exchanger includes a plurality of heat exchange plates stacked to enclose flow channels for the first and second fluids between the plates, a first intermediate plate pair sandwiched between a first and second stack of the heat exchange plates, and a barrier located between the plates of the intermediate plate pair to separate the first fluid from the second fluid. The intermediate plate pair includes a first fluid port extending laterally from the heat exchanger to transfer the first fluid between the heat exchanger and a device other than the heat exchanger. The intermediate plates are joined to enclose a first chamber, with the first chamber opening to the first fluid port and to a manifold for the first fluid to direct the first fluid between the first fluid port and the manifold.

Abstract: A flat heat exchanger tube formed of a single strip of rolled aluminum, with at least one connection between the two broad sides. The connection is generally parallel to and spaced between the narrow sides and divides the heat exchanger tube into at least two chambers, and includes two legs consisting of bent opposite edges of the aluminum strip, the legs each having a head at adjacent bends along one of the broad sides and feet adjacent the other broad side. The legs lie against each other generally at their head over no more than half of the entire spacing between the two broad sides, with the legs enclosing an angle between them of about 20° to 100° or about 45° to 75°, advantageously 60°.

Abstract: An insert adapted to connect to opposite walls in a heat exchanger tube, including a corrugated sheet having alternating wave crests and wave troughs connected by wave flanks having openings therein, wherein at least some of the wave crests have a length different than the length of the wave troughs, and/or adjacent sections have different wavelength waves. Such inserts may be produced by transporting material sheets through a press, where the sheet feed rate and/or the press stroke speed may be selectively varied.

Abstract: A housing-less plate heat exchanger is provided for transferring heat between at least a first fluid and a second fluid. The heat exchanger includes a plurality of heat exchange plates stacked to enclose flow channels for the first and second fluids between the plates, a first intermediate plate pair sandwiched between a first and second stack of the heat exchange plates, and a barrier located between the plates of the intermediate plate pair to separate the first fluid from the second fluid. The intermediate plate pair includes a first fluid port extending laterally from the heat exchanger to transfer the first fluid between the heat exchanger and a device other than the heat exchanger. The intermediate plates are joined to enclose a first chamber, with the first chamber opening to the first fluid port and to a manifold for the first fluid to direct the first fluid between the first fluid port and the manifold.