Abstract: A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

Abstract: A header for a header tank of a heat exchanger comprises a header wall defining a tube receiving portion having a plurality of longitudinally spaced tube openings formed therethrough. The tube receiving portion includes a planar portion and an adjacent offset portion. The planar portion is disposed on a first plane and the offset portion has a variable distance from the first plane as the offset portion extends away from the planar portion with respect to a longitudinal direction of the header.

Abstract: A header for a header tank of a heat exchanger comprises a header wall defining a tube receiving portion having a plurality of longitudinally spaced tube openings formed therethrough. The tube receiving portion includes a planar portion and an adjacent offset portion. The planar portion is disposed on a first plane and the offset portion has a variable distance from the first plane as the offset portion extends away from the planar portion with respect to a longitudinal direction of the header.

Abstract: A heat exchanger for a vehicle includes a heat exchanger core. The heat exchanger core is configured to exchange heat between fluids. The heat exchanger further includes a header. The header is in fluid communication with the heat exchanger. A bracket is coupled to the header by a cold forming process.

Abstract: A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

Abstract: A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

Abstract: A folded tube for a heat exchanger is disclosed. The tube includes first and second ends for connection to first and second headers of the heat exchanger. An outer wall of the tube provides at least two channels for carrying a heat exchange fluid between the first and second headers. At least one seam is formed in the outer wall extending the length of the tube, the seam including a pair of opposed flanges extending into the tube to form the two channels, the outer wall joined together along the seam. The tube further includes a first end region and a second end region, and an intermediate region. The tube flattened along its length to form at least two flattened lobes, each lobe including one of the channels, and the lobes in the intermediate region being flatter than the lobes in at least one of the end regions.

Abstract: A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

Abstract: A receiver dryer for a motor vehicle air conditioning system includes an elongate housing, the housing having opposite ends and an external wall that extends between the ends, an inlet positioned in a first section of the housing for receiving condensed refrigerant from the condenser unit, an outlet positioned in a second section of the housing for providing dried condensed refrigerant to the condenser unit with a partition dividing the first section from the second section such that the second section is above the first section, a first chamber in the first section containing a desiccant for drying the refrigerant received from the inlet, a second chamber in the second section containing a filter for filtering the dried condensed refrigerant provided to the outlet, and a conduit.

Abstract: A folded tube for a heat exchanger is disclosed. The tube includes first and second ends for connection to first and second headers of the heat exchanger. An outer wall of the tube provides at least two channels for carrying a heat exchange fluid between the first and second headers. At least one seam is formed in the outer wall extending the length of the tube, the seam including a pair of opposed flanges extending into the tube to form the two channels, the outer wall joined together along the seam. The tube further includes a first end region and a second end region, and an intermediate region. The tube flattened along its length to form at least two flattened lobes, each lobe including one of the channels, and the lobes in the intermediate region being flatter than the lobes in at least one of the end regions.

Abstract: A header for a heat exchanger includes an elongate header plate having a pair of substantially parallel long edges. The header plate includes an elongate slot extending in a first direction across the header plate and a pair of ridges extending in a second direction along the header plate. The second direction is substantially perpendicular to the first direction. Edge regions of the header plate are formed on sides of the ridges adjacent the long edges. At least one of the edge regions lie in a first plane and crests of the ridges lie in a second plane. The first plane is substantially parallel to and offset from the second plane.

Abstract: A receiver dryer for a motor vehicle air conditioning system includes an elongate housing, the housing having opposite ends and an external wall that extends between the ends, an inlet positioned in a first section of the housing for receiving condensed refrigerant from the condenser unit, an outlet positioned in a second section of the housing for providing dried condensed refrigerant to the condenser unit with a partition dividing the first section from the second section such that the second section is above the first section, a first chamber in the first section containing a desiccant for drying the refrigerant received from the inlet, a second chamber in the second section containing a filter for filtering the dried condensed refrigerant provided to the outlet, and a conduit.