Abstract: A heat exchanger includes a pair of tanks, each of the tanks having a pair of baffles sealingly engaged to a center wall, a pair of sidewalls, and a cover to form a fluid tight seal therebetween and provide a closure to the tank, wherein each of the sidewalls includes a portion of at least one of a pin and bracket for mounting the heat exchanger.

Abstract: A header for a heat exchanger includes a substantially planar base portion and a pair of step portions. The step portions are angled from the plane of the base portion. The header is also provided with a plurality of substantially parallel slots spaced apart along the length of the header. Each slot has an elongate section extending across the width of the base portion and end sections extending from the elongate section into the step portions of the header.

Abstract: A heat exchanger includes a first section and a second section for cooling distinct fluids, wherein the second section is adapted for cooling oil. The heat exchanger includes first and second manifolds divided by baffles into first and second chambers. A plurality of tubes connect the manifolds in fluid communication with the first chambers to form the first section of the heat exchanger. A plurality of oil cooling tubes connect the manifolds in fluid communication with the second chambers to form the second section. The oil cooling tubes have a cross-section characterized by a performance ratio between about 3.9 and 8.5 wherein the performance ratio is the ratio of the wetted perimeter in millimeters divided by the cross-sectional area of tube metal in square millimeters. The oil cooling tubes may be formed of extruded metal with internal fins or an extruded tube having a stamped metal insert.

Abstract: A heat exchanger for a vehicle is provided, where the heat exchanger includes core having first, and second sets of flow tubes extending between first and second headers and defining separate flow paths. One of the headers includes a first portion in fluid communication with the first set of flow tubes and a second portion defining a receiver/dryer chamber that is in fluid communication with the second set of flow tubes. A dryer is located within the receiver/dryer chamber.

Abstract: A heat exchanger includes a first section and a second section for cooling distinct fluids, wherein the second section is adapted for cooling oil. The heat exchanger includes first and second manifolds divided by baffles into first and second chambers. A plurality of tubes connect the manifolds in fluid communication with the first chambers to form the first section of the heat exchanger. A plurality of oil cooling tubes connect the manifolds in fluid communication with the second chambers to form the second section. The oil cooling tubes have a cross-section characterized by a performance ratio between about 3.9 and 8.5 wherein the performance ratio is the ratio of the wetted perimeter in millimeters divided by the cross-sectional area of tube metal in square millimeters. The oil cooling tubes may be formed of extruded metal with internal fins or an extruded tube having a stamped metal insert.

Abstract: An apparatus is disclosed for supporting and sealing a heat exchanger unit. Specifically, a unitary header and tank unit is disclosed comprising a condenser header and tank unit arranged in parallel relation to a radiator header and tank unit. The unitary header and tank unit is formed from a single piece of stamped material. The single piece of material is stamped to include a perpendicular extrusion and two base portions, each base portion being perforated. The partial separation of the perpendicular extrusion into two flange portions allows the base portions to be folded over onto the flange portions thereby forming two header and tank units with a single internal partition. Additionally, a fin unit is disclosed that is capable of traversing the heat exchange fins of multiple heat exchangers.

Abstract: A condenser assembly for a vehicle air conditioning system. The condenser assembly includes a core comprised of a plurality of parallel tubes between which are located a plurality of fins. A pair of headers are located on opposite ends and in fluid communication with the tubes of the core. The headers are constructed such that their primary components exhibit constant cross sectional profiles along their lengths. This enables the volumetrics of the condenser assembly to be altered with a minimal amount of tooling change over being required.

Abstract: A tube and method of making the same for a heat exchanger includes a base, a top spaced from and opposing the base, a first side interposed between the base and the top along one side thereof, and a second side interposed between the base and the top along another side thereof. The tube includes an end form formed solely on either one of the first side and the second side to create a stop for inserting said tube into a manifold of the heat exchanger.

Abstract: A turbulator with offset louvers and method of making the same for a heat exchanger includes a plurality of corrugated fins each having a base extending laterally and longitudinally in a strip. The turbulator also includes a plurality of louvers spaced along the base and extending longitudinally and generally perpendicular to the base in an alternating manner, the louvers being rolled in a direction parallel to a longitudinal axis of the strip.

Abstract: A tube and method of making the same for a heat exchanger includes a base, a top spaced from and opposing the base, a first side interposed between the base and the top along one side thereof, and a second side interposed between the base and the top along another side thereof. The tube includes an end form formed solely on either one of the first side and the second side to create a stop for inserting said tube into a manifold of the heat exchanger.

Abstract: An apparatus is disclosed for supporting and sealing a heat exchanger unit. Specifically, a unitary header and tank unit is disclosed comprising a condenser header and tank unit arranged in parallel relation to a radiator header and tank unit. The unitary header and tank unit is formed from a single piece of stamped material. The single piece of material is stamped to include a perpendicular extrusion and two base portions, each base portion being perforated. The partial separation of the perpendicular extrusion into two flange portions allows the base portions to be folded over onto the flange portions thereby forming two header and tank units with a single internal partition. Additionally, a fin unit is disclosed that is capable of traversing the heat exchange fins of multiple heat exchangers.

Abstract: A method for attaching mounting features to an aluminum heat exchanger tank during its formation is provided. A mounting feature with at least one extension protruding from it is provided and a heat exchanger tank is formed with at least one opening defined in it, apart from fluid flow openings. The method includes the step of attaching the mounting feature to the tank such that the extensions are received within the openings in the tank and the extensions are deformed to secure the mounting feature in place.

Abstract: An apparatus is disclosed for supporting and sealing a heat exchanger unit. Specifically, a heat exchanger is disclosed comprising a pair of integrated header units arranged in parallel relation to each other. Each header unit comprises a radiator header and a condenser. The radiator unit and condenser maintain separate heat exchange fluid flowpaths. A plurality of parallel heat transfer tubes is connected perpendicularly to said integrated headers, and a plurality of fins extend between adjacent heat transfer tubes of the radiator. A fin unit including a plurality of fins is mounted to an outside surface of an outermost heat transfer tube, and an integrated side support is connected to the fin unit and integrated headers.

Abstract: A turbulator with offset louvers and method of making the same for a heat exchanger includes a plurality of corrugated fins each having a base extending laterally and longitudinally in a strip. The turbulator also includes a plurality of louvers spaced along the base and extending longitudinally and generally perpendicular to the base in an alternating manner, the louvers being rolled in a direction parallel to a longitudinal axis of the strip.

Abstract: A condenser includes a plurality of generally U-shaped fluid carrying tubes having free ends and a manifold matingly engaging the free ends of the tubes and having an interior chamber. The manifold includes a receiver dryer disposed in the interior chamber and having a first fluid conduit wall and a second conduit wall extending axially to form a generally parallel first fluid passageway and second fluid passageway in fluid communication with the tubes and a dryer capsule being disposed in the interior chamber to dry fluid in the manifold.

Abstract: A heat exchanging device is disclosed. The device includes a fluid flow tube having a turbulator which includes a plurality of coil sections. Each of the coil sections includes a number of coil members of uniform diameter. The coil sections are spaced apart by a predetermined number of other coil members having smaller diameters and different heights than the coil members in the coil sections. These coil configurations force fluid flowing around them into heat exchanging contact with the tube walls.

Abstract: A heat exchanger having a plurality of elongated, generally flat tubes is disclosed, each tube including a planar base, a top, and pair of arcuate opposed side portions interposed between the base and the top is disclosed. A partition extends from the top to the base to define a pair of fluid passageways, the partition including a pair of opposing, contacting shoulder portions and a leg portion depending from each of the shoulder portions which contact the base. A first braze receiving of predetermined size is defined between the shoulder portions and the manifold of the heat exchanger. The size of the braze receiving area is controlled by minimizing the curvature of the shoulder portions.

Abstract: A heat exchanger for an automotive vehicle is disclosed including a frame having a pair of headers and a pair of side supports disposed between the headers at opposite ends thereof. Each of the side supports includes a generally planar base and a pair of flanges extending from the based portion. The side supports including a stress relieving-zone defined by a Z-shaped aperture disposed in the base portion.

Abstract: There is disclosed herein a method for forming a manifold for a heat exchanger. The method includes the steps of the forming a generally planar sheet of material into a generally cylindrical member having a seam along the longitudinal length thereof. The method further includes forming a plurality of tube receiving slots in the cylindrical member and applying a pressure against the seam so as to flatten the seam.

Abstract: A method for making a heat exchanger tube having an elongated, generally rectangular member including a planar base, a top, and pair of arcuate opposed side portions interposed between the base and the top. A partition extends from the top to the base to define a pair of fluid passageways, the partition including a pair of opposing, contacting shoulder portions and a leg portion depending from each of the shoulder portions which contact the base. A first braze receiving of predetermined size is defined between the shoulder portions and the manifold of the heat exchanger. The size of the braze receiving area is controlled by minimizing the curvature of the shoulder portions.