Abstract: An air-to-air aftercooler may include at least one tube body configured to direct a flow of charged air, wherein the at least one tube body includes a first material. The air-to-air aftercooler may also include a header assembly coupled to ends of the at least one tube body. The header assembly may include a second different material.

Abstract: A heat exchanger, a reinforced header assembly for use in a heat exchanger, and a method of assembling a heat exchanger. The reinforced header assembly may include a header connectable with a tank to define a collection tank assembly, the header including a central portion defining a plurality of header openings, and a connecting portion connectable to the end of the tank wall such that the tank portion and the header cooperate to define the collection tank assembly, the connecting portion including a wall extending at a non-parallel angle relative to the central portion, and a reinforcement member including an inner portion defining a plurality of member openings, and an outer portion extending at a non-parallel angle relative to the inner portion, the outer portion being complementary to and connected to at least a portion of the wall of the connecting portion of the header.

Abstract: A cooling manifold and a method for manufacturing the cooling manifold are provided. The cooling manifold includes a housing that defines an interior region having a serpentine flow path therein. The housing has a first plurality of grooves extending from a first surface of the housing into the housing. The grooves do not fluidly communicate with the interior region. The first plurality of grooves receive a portion of a thermally conductive member therein to conduct heat energy from the thermally conductive member to the housing. The cooling manifold further includes a top cap configured to seal a first end of the housing and a bottom cap configured to seal a second end of the housing.

Abstract: Each header tank includes a tank body and a header plate. The tank body includes a top wall, shorter side walls, and longer side walls. Each shorter side wall has joining portions integrally formed via rounded connection portions and extending along the inner surfaces of the longer side walls. The header plate includes a closure wall, shorter side walls, and longer side walls. End portions of each longer side wall of the tank body are curved along the rounded connection portions to form first bent portions. End portions of each longer side wall of the header plate are curved along the first bent portions to form second bent portions. The shorter side walls of the header plate have deformation portions which enter recesses formed between the rounded connection portions of the tank body and tip end surfaces of the first bent portions.

Abstract: A multi-chamber heat exchanger header includes a header housing and an insert. The header housing has a first wall and a second wall generally opposite the first wall where the first and second walls define a track. The insert is positioned to engage with the track such that the insert separates the header into first and second manifold chambers. A method for forming a multi-chamber heat exchanger header includes extruding a header housing having first and second manifold chambers and a track, positioning an insert in the header housing to engage with the track, and welding or brazing the insert to the header housing.

Abstract: A manifold for use in a heat exchanger assembly and a method of forming the manifold is disclosed herein. The assembly includes an upper manifold defining an interior and having a upper top portion having an upper opening in the center of said upper top portion. A partition is inserted through the upper opening to define a plurality of chambers in the interior. The partition has a plurality of locking tabs and dimples that abut the upper top portion. The method starts with the step of forming the upper manifold defining an interior and having an upper top portion defining an upper opening in the center of the upper top portion. The method continues with the step of dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold and is finalized by joining the partition and the upper manifold through a snap fit.

Abstract: A refrigerant leak-preventive structure in a heat exchanger is described. The refrigerant leak-preventive structure includes a tube group having refrigerant leak-preventive grooves recessed at ends of the fin-tubes group, and headers having refrigerant leak-preventive projections formed by double injection molding solution introduced into and cooled in the refrigerant leak-preventive grooves when being coupled with the both ends of the tube group by a double injection molding.

Abstract: A method of manufacturing a heat exchanger core, including providing a plurality of flat tubes having a plurality of flow channels therein, forming at least a portion of each of said flat tubes to define an arcuate tube cross-section, piercing a first and a second header to produce a series of slotted openings therein, assembling the first and second headers to first and second ends, respectively, of the plurality of tubes, and placing the assembled tubes and headers into an elevated temperature environment to cause a braze alloy cladding on either the tubes or the headers or the tubes and the headers to flow and form brazed joints between the tubes and headers. Forming the portion of each of said flat tubes to define the arcuate tube cross-section includes forming an arc extending between an air inlet side and an air outlet side of the tube.

Abstract: A manifold assembly for a heat exchanger is manufactured and assembled by separately molding a tank portion and a header portion, and assembling the tank and header portions together by positioning them relative to each other and injecting a sealing substance in a cavity that is formed when the portions are so positioned. Ribs are incorporated in the tank and header portions to increase the interface area between the molded portions and the sealing substance, to achieve a mechanically sound, leak proof assembly without using gaskets or fasteners.

Abstract: A heat exchanger manifold with improved sealing between the tank and header. The manifold includes a plastic heat exchanger tank having an opening for mating with a header and a lip extending substantially around a periphery of the opening. The lip has an outer surface and an upper surface extending outward of the tank opening, and a ridge extending upward from a portion of the upper surface extending substantially around the tank. The manifold further includes an aluminum heat exchanger header adapted to connect to a heat exchanger core. The header has a groove around the periphery thereof receiving the tank lip and a plurality of plastically deformable tabs extending from an edge of the groove. The tabs are bent inward and contact the ridge on the tank lip to secure the tank to the header.

Abstract: Provided is a heat exchanger, heat sink or coldwall having a machined manifold for receiving a plurality of individual, modular micro-channel heat exchanger elements. The manifold further includes a parallel flow network or flow distribution network for distributing a cooling fluid uniformly to all micro-channel heat exchanger elements. Each micro-channel heat exchanger element is individually manufactured and tested prior to integration with the manifold. The design of the micro-channel heat exchanger elements may include a straight fin, a high density fin, lanced offset fin, and perforated offset layers fin configurations.

Abstract: A method of manufacturing a brazed pipe comprises steps A to D. In the step A, on an upper surface of the right-hand side edge portion of a material plate 20 having a brazing material layer over opposite surfaces thereof, a first slant surface 21 is formed such that it inclines from the upper side toward the lower side while approaching the right end, and a first flat surface 22 is formed between the first slant surface 21 and the lower surface. In the step B, on a lower surface of the left-hand side edge portion of the material plate 20, a second slant surface 24 is formed such that it inclines from the lower side toward the upper side while approaching the left end, and a second flat surface 25 is formed between the second slant surface 24 and the lower surface.

Abstract: A heat exchanger assembly having an inlet header, an outlet header spaced apart from and substantially parallel the inlet header, and a plurality of refrigerant tubes each extending between and in hydraulic communication with the inlet header and outlet header. Contained within the outlet header is a refrigerant collector conduit adapted to provide a predetermined pressure drop (?P) and having a cross-section area Acollector. The refrigerant collector includes a plurality of orifices having a cumulative orifice area (nAorifice) that are substantially equally spaced along the refrigerant collector. The collector conduit is in fluid communication with the outlet header for transferring the vapor phase of a two refrigerant. The collector conduit cross sectional area (Acollector) and cumulative orifice area (nAorifice) is described by the following equation: ? ? ? p = m dot 2 ? ? [ 467.892 ? ( 1 A collector 2 - 1 n 2 ? A orifice 2 ) + 51.

Abstract: A stacking-type, multi-flow, heat exchanger includes a plurality of heat transfer tubes and fins stacked alternately, a tank formed at an end of the heat transfer tubes, and an end plate provided at an end of the tank. The heat exchanger has a projecting portion provided to a surface of an outermost tube plate, a raised portion with an opening formed through the projecting portion, and an engaging portion and a closing portion provided integrally to the end plate for engaging the raised portion and for closing an opening of the raised portion. A positional shift of the end plate at the time of temporary assembling may be prevented, and the brazing properties and the pressure resistance of the tank end portion may be increased.

Abstract: Heat exchanger assemblies, and in particular, heat exchanger assemblies for automotive vehicle applications are disclosed. The heat exchangers have manifolds with retention tabs for brackets, caps and other components, such as attachment elements.

Abstract: A heat exchanger for a motor vehicle, particularly a motorcycle in which a bent cooling element is disposed between a first and second collector tank. The bent cooling element is provided with a longer and a shorter side as well as lateral connecting planes for joining the cooling element to the collector tanks. The collector tanks are made of a material that has substantially lower strength than the material of the cooling element.

Abstract: A manifold for a heat exchanger includes a header radially surrounding and in spaced relationship to an axially extending distributor conduit. The distributor conduit is formed by bending the sheet along the leading edge, and the header is formed by bending a remainder of the sheet including a trailing edge about an axis in radially spaced relationship to the distributor conduit. The cross sections are completed and closed by placing the leading and trailing edges into contact with, and sealing the edges to the sheet.

Abstract: A stamped manifold for a heat exchanger includes a central portion having a plurality of mating tubular members for connection to tubes of a heat exchanger. The manifold includes a plurality of folds disposed between the mating tubular members to form a pair of channels below a plane of the central portion and a central fold above the plane of the central portion. The manifold includes a first extension member extending from a side edge of the central portion and a second extension member extending from another side of the central portion and opposing the first extension member. The free ends of the first extension member and the second extension member are disposed in the pair of channels in contact with the central fold and secured in place to define a first fluid conduit and a second fluid conduit.

Abstract: A method of manufacturing a manifold of a heat exchanger is provided. The manifold has an outer wall and an inner tube with a cavity formed there between. The method utilizes a punch having a first cusp and a second cusp and includes the step of lancing the outer wall of the manifold utilizing both the first and second cusps to form a first aperture in the outer wall and to dispose the first and second cusps in the cavity. The method also includes the steps of moving the first and second cusps through the cavity toward the inner tube while maintaining at least one of the first and second cusps within the cavity and lancing the inner tube of the manifold utilizing the second cusp to form a second aperture in the inner tube. The method still further includes the step of retracting the punch from the manifold.

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: The present invention relates to a heat exchanger having a cooling core consisting of a plurality of parallel, heat exchanging tubes and two manifolds provided with slots, where the ends of heat exchanging tubes are inserted in fluid connection with each manifold and each slot is defined by a slot opening and parallel-running slot walls formed from deformed wall portions of the manifold. In order to improve a rigidity of construction of the heat exchanger the outer sides of said slot are deformed inwardly relative to the manifold wall, forming concavities in the manifold outer surface, the inner sides of said slot are deformed inwardly relative to the manifold wall, forming convexities in the manifold inner surface, and the convexities comprise grooves forming the slot walls in order to accommodate at least a portion of the longitudinal edges of the end of exchanging tube. A method of manufacturing such a heat exchanger manifold is also provided.

Abstract: The present invention relates to the field of automotive heat exchangers, and, in particular, to heat exchanger tanks with headers. This invention eliminates the need for use of an inner flange on the header using a collar that also acts as a rib, thereby providing a compact foot plus header tank arrangement with lower stress on the gasket mating surface of the header and tank. The present invention also provides a method for providing improved headering means for automotive heat exchangers with plastic tanks and headers.

Abstract: A header tank for a heat exchanger includes tank forming sections that are joined into a tubular shape with a substantially square cross-section. The header tank has a refrigerant low path formed inside the tank forming sections include a tank upper section (31) in which tube insertion holes (31a) for connecting tubes of a heat exchanger core are formed. The tank lower section (33) having a substantially U-shaped refrigerant split-flow groove (33A) that has, in its longitudinal direction, communication holes (33a, 33b) for the refrigerant. The tank forming sections include a plate section (35) for closing an opening of the refrigerant split-flow groove (33A) to form a refrigerant split-flow path (37) inside the tank lower section.

Abstract: The invention relates to a process for the arc welding of at least one metal workpiece to a matrix comprising at least one brazed zone, the braze of which contains copper and phosphorus, in which (a) at least one layer of an alloy containing copper and more than 1% tin by weight is deposited on at least one part of the brazed zone and (b) the metal workpiece is welded to the said at least one layer of copper/tin alloy deposited in step (a). The invention relates to a process for manufacturing a brazed copper heat exchanger using the at least one layer of copper/tin alloy. The brazed copper heat exchanger may be used in the cryogenic separation of gases.

Abstract: A heat exchanger is disclosed having a pair of tanks, the tanks including a center wall, a first sidewall, a second sidewall, a pair of baffles, and a cover, wherein the center wall, the first sidewall, and the second sidewall are integrally formed to minimize a complexity of manufacture and assembly.

Abstract: Manifolds and manifold connections for heat exchangers are disclosed. One embodiment includes an elongate tubular body with a central cavity. The body has an elongate retainer formed therealong. An attachment member is received by the retainer and an insert is retained between the tubular body and the attachment. The insert is formed from a material having a melting temperature less than that of the tubular body and the attachment member. The manifold may be heated to a temperature greater than the melting temperature of the insert material and subsequently cooled so that the insert joins the attachment member to the body.

Abstract: Modular manifolds for heat exchangers are disclosed with a primary tube disposed alongside a heat exchanger with a port disposed adjacent to ports of the heat exchanger. A manifold block is provided with a port mounted to the primary tube for fluid communication with the primary tube. The manifold block includes a plurality of back extruded ports for direct communication with the ports of the heat exchanger. Additionally, a method is disclosed for manufacturing a modular manifold for heat exchangers.

Abstract: A secondary heat exchanger subassembly, such as a transmission oil cooler, is disposed in a metal tank of a radiator and has a pair of metal fluid fittings. Either a connector ring engages a fitting extending through the opening in the tank or a connector nut extends into the opening to threadedly engage the fitting whereby the metal fittings are held to the metal tank and inserted into a furnace for being brazed into sealed relationship with the metal tank.

Abstract: Each header tank includes a tank body and a header plate. The tank body includes a top wall, shorter side walls, and longer side walls. Each shorter side wall has joining portions integrally formed via rounded connection portions and extending along the inner surfaces of the longer side walls. The header plate includes a closure wall, shorter side walls, and longer side walls. End portions of each longer side wall of the tank body are curved along the rounded connection portions to form first bent portions. End portions of each longer side wall of the header plate are curved along the first bent portions to form second bent portions. The shorter side walls of the header plate have deformation portions which enter recesses formed between the rounded connection portions of the tank body and tip end surfaces of the first bent portions.

Abstract: According to a method for producing head elements for heaters, a piece of sheet metal (1) is deep drawn and cut along the edge (9) of an open side (6) to obtain a hollow body (8) with larger and narrower sides (4,5,14,15). An aperture (12) is made on each opposite larger side (4,5) of the hollow body, and threaded rings (26) are then applied around the lateral through apertures (12). Notches (16) are made on the opposite large sides (4,5), along the edge (9) of the open side (6), and then three cores (18) are introduced through the edge (9), so that a flange (17) around the notches (16) can be made by pressing, so as to close the sheet metal (1) around the cores (18) widening the notches (16). After the cores (18) have been removed, the edge (9) is welded along the flange (17) of the widened notches (16), thus obtaining holes (21) separated from each other.

Abstract: The present invention relates to a heat exchanger having a cooling core consisting of a plurality of parallel, heat exchanging tubes and two manifolds provided with slots, where the ends of heat exchanging tubes are inserted in fluid connection with each manifold and each slot is defined by a slot opening and parallel-running slot walls formed from deformed wall portions of the manifold. In order to improve a rigidity of construction of the heat exchanger the outer sides of said slot are deformed inwardly relative to the manifold wall, forming concavities in the manifold outer surface, the inner sides of said slot are deformed inwardly relative to the manifold wall, forming convexities in the manifold inner surface, and the convexities comprise grooves forming the slot walls in order to accommodate at least a portion of the longitudinal edges of the end of exchanging tube. A method of manufacturing such a heat exchanger manifold is also provided.

Abstract: A refrigerant leak-preventive structure in a heat exchanger is described. The refrigerant leak-preventive structure includes a tube group having refrigerant leak-preventive grooves recessed at ends of the fin-tubes group, and headers having refrigerant leak-preventive projections formed by double injection molding solution introduced into and cooled in the refrigerant leak-preventive grooves when being coupled with the both ends of the tube group by a double injection molding.

Abstract: The present invention comprises a heat exchanger and method for sealing a heat exchanger tube to a header of the heat exchanger. The method comprises melt-bonding the tube to a header of the heat exchanger to form a bond and sealing the bond with a sealant material to form a seal.

Abstract: A collar for a fin-tube heat exchanger is provided. The collar extends outwardly from a thermally conductive plate in order to receive a tube. The collar generally includes a wall having a proximal end integral to the conductive plate, and a distal end defining an opening configured for receiving a tube. The wall includes a reflare portion at its distal end, with the reflare portion being curled into either the inner diameter or the outer diameter of the wall. Preferably, the reflare portion is curled into the inner diameter of the wall, and then further flared outwardly to form a double flare. A method for forming the double flare collar is also provided. The method involves progressively moving fin stock through a metal-stamping machine in order to sequentially form double flare collars.

Abstract: A modular heat exchanger suitable for automotive applications, and methods for forming the modular heat exchanger. The modular heat exchanger construction incorporates a monolithic brazed core assembly composed of flat-type cooling tubes and sinusoidal centers. The required positional tolerances of the tubes for mating with the remainder of the heat exchanger are maintained within the brazed core assembly by minimizing core shrinkage resulting from the brazing operation during which the tubes are brazed to the centers.

Abstract: The invention relates to a method for producing a plate heat exchanger from a plurality of heat exchanger blocks (1a, 1b). Each heat exchanger block (1a, 1b) has mounted on it a header (6a, 7a, 6b, 7b) which extends over at least part of one side of the heat exchanger block (1a, 1b). The heat exchanger blocks (1a, 1b) are arranged next to one another, and the headers (6a, 6b; 7a, 7b) of two adjacent heat exchanger blocks (1a, 1b) are provided on their mutually confronting sides with orifices and are connected to one another in such a way that a flow connection occurs between the two headers (6a, 6b; 7a, 7b).

Abstract: This invention provides an improved system and method for producing manifolds such as those used to direct exhaust gasses from an internal combustion engine into a turbocharger. The manifold is made from two or more pieces which are machined in such a way as to create passageways when the separate pieces are assembled together. The method is much faster and easier to produce than present methods and allows for improved accuracy. The ability to machine these manifolds using computer controlled machines will lower costs and improve quality.

Abstract: A flat tube having a nearly B-like shape or the like in cross section, which has one or more partitions therein, and is coated with a brazing metal on the outer surface thereof, is provided. In the top portion of the turned-up portion constituting the partition, there are formed many slits, in order to provide the conditions that satisfy both of the brazing performance and an increase of working accuracy of the flat tube, which slits allow the brazing metal to enter up to the top portion of the turned-up portion, wherein the length “c” of the slit is 2 mm to 15 mm; the distance “e” between the edges of the neighboring slits is 3 mm to 10 mm; and “e/c” is 0.6 or more.

Abstract: In a process for the production of half-tubes or tubes of a recuperative waste gas heat exchanger using a precision casting process, the half-tubes or tubes consisting of a high-temperature-resistant metallic material have a plurality of elliptical openings passing through their surface.

Abstract: The invention relates to a soldered heat exchanger, especially a capacitor for a motor vehicle ventilation system, comprising a heat exchanger network made of tubes and ribs and at least one collector pipe made of a base (2) and a cover (3) and separating walls (8), whereby the base (2) and the cover (3) have edges (4, 5, 6, 7) which overlap on the longitudinal sides thereof. The base (2) receives the ends of the tubes and the separating walls (8) are fixed in relation to the cover (3) by means of a first and second shoulder (8b, 8c and a lug (8a). According to the invention, groove-shaped recesses (3b, 3c) are arranged in the edges (6, 7) of the cover (3) in the region of the separating walls (8), wherein the shoulders (8b, 8c) of the separating walls (8) engage. A secure positioning of the separating walls in the collector pipe is obtained in addition to a leakage-free soldering of the capacitor.

Abstract: A metal tank cap is integral with a reinforcing member via a narrow connection and is flared outwardly at the narrow connection portion to be over an open end of the tank simultaneously with moving the metal tubes of the core into the tank. By unbending the connection portion, the respective tank caps are deflared into the open ends of the respective tanks and the entire assembly is placed in a furnace and brazed together.

Abstract: A one-piece header tank includes side edges that are overlapped and brazed together to form a joint positioned within the interior of the tank. The tank also includes an integrally formed mounting flange that may be fabricated without jeopardizing the leak integrity of the tank.

Abstract: The invention relates to a collector tube (1) for a heat transfer unit. The tube comprises one or several slits (3d) on the periphery thereof, whereby said slits are formed by a punch press without an inner die or by high-pressure shaping for inserting a respective flat tube. The invention also relates to a method for producing said collector tube (1). According to the invention, a collector tube (1) is provided with an outer radius (D/2) to tube wall thickness (s) ratio of less than 5. The slits (3d) are introduced preferably parallel to, or at an acute 2 angle to the longitudinal axis of the tube. The collection tube can be produced by bending a flat material and subsequently sealing the longitudinal slits arising from the bending process by soldering or welding. Said collector tube can be used, e.g. for gas coolers and evaporators for CO2 air conditioning systems in motor vehicles.

Abstract: A method of forming a jacketed steam distribution tube assembly includes simultaneously extruding an inner tube, an outer tube, and a plurality of connecting members for connecting the inner tube to the outer tube, thereby forming a jacketed steam distribution tube assembly.

Abstract: In a method of applying a brazing material to braze a joining portion between a first member and a second member, a relationship between an amount of the brazing material and an expanding dimension of the brazing material is determined. Then, a position to apply the brazing material or a necessary amount of the brazing material is decided based on the relationship. After the first member and the second member are joined, the brazing material is applied. The position is defined by a distance from the joining portion. The distance is set smaller than one-half the expanding dimension of the brazing material on an applying surface.

Abstract: A system to construct a manifold from an original material. A first progressive die implements a first set of stamping stages on the original material to generate a shaped material. A second die implements at least one of a second set of stamping stages on the shaped material to generate a finished manifold. The second die is physically separate from the first die.

Abstract: A metal plate comprises two flat wall forming portions 89, 90 connected together by a joint portion 88, a plurality of reinforcing wall forming portions 83, 84 upwardly projecting from each of the wall forming portions 89, 90 integrally therewith, and a side wall forming portion 81, 82 formed at each of opposite side edges of the plate and upwardly projecting therefrom integrally therewith. A projection 85 is formed on the upper end of the reinforcing wall forming portion 83 on the flat wall portion 89, and a recess 86 for the projection 85 to fit in is formed in the upper end of the wall forming portion 84 to be butted against the portion 83 and provided on the other flat wall portion 90. The metal plate satisfies the relationships of: A>a, A/a≦1.5, B/b≦1.5, C/c≦1.5, and D/d≦1.

Abstract: A compression limiter formed by a roll forming process includes a substantially cylindrical body portion and a plurality of feet. A plurality of notches are stamped along a lower edge of a flat sheet of stock and bent to form the plurality of feet. The flat sheet of stock is then rolled to form the compression limiter. In the preferred embodiment, the compression limiter is formed of a high carbon steel. The plurality of feet of the compression limiter transmit the bolt load of a fastener attaching a plastic intake manifold to a component. In an alternative embodiment, an angled portion attaches each foot to the body of the compression limiter which accommodates for variations in the height of the plastic intake manifold.

Abstract: An extruded D-shaped manifold machined from extruded tubing is generally D-shaped in cross-section, with the header being thicker than the tank. At least two longitudinal external ribs are formed on the header exterior, preferably positioned symmetrically relative to the longitudinal axis of the header. The external ribs provide additional strengthening of the header and act as stops to prevent the heat exchanger fins from contacting the tube/manifold joint (which can lead to leakage when the joint is brazed). The number of external ribs and their location depend on the size of the manifold and the precision required in positioning the heat exchanger tubes in the slots. The manifold can be extruded with lengthwise internal ribs extending along the interior sides of the tank to act as stops for the heat exchanger tubes.

Abstract: The invention relates to a method for forming at least one flat-tube insertion slot in a header tube. A sawcut is introduced into the header tube during a sawing step, and the slot is configured, during a subsequent punching step, by means of a slot punch, which punches into the region of the sawcut. A rimmed opening can be configured during the punching step by using a slot punch with a larger width and/or length relative to the sawcut. The sawcut is preferably introduced to a depth less that the wall thickness of the header tube. The respective web region(s) between chamber of a multi-chamber header tube can be compressed during the punching operation to a level lower than that of a header-tube wall region functioning as a flat-tube insertion stop, in order to form a chamber-connecting duct.