Gm Global Technolgoy Operations, Inc.

Delphi Technologies, Inc.

David M Smith

Gary A Halstead

Richard P Ryan

David E Samuelson

Don C Corser

Richard Victor Cooper, Jr

Shrikant M Joshi

Karl Paul Kroetsch

Joel Thomas Hambruch

Christopher Alfred Fuller

Steve C Brick

Glenn W Shaffer

A communication plate extends along and is sandwiched between cylindrical communication manifolds of a first heat exchanger assembly and a second heat exchanger assembly. The communication plate includes a saddling surface arcuate in one direction and a saddling surface arcuate in the opposite direction for engaging in saddle-like fashion the cylindrical shape of the manifolds. The communication plate defines a plurality of communication plate orifices disposed along the communication plate and aligned co-axial with a plurality of communication orifices disposed along the manifolds to seal the communication orifices of the manifolds and establish distributed and sealed fluid communication between the heat exchanger assemblies.

Manifold fluid communication plate

A heat exchanger assembly includes a core having first and second header tanks covered by tank caps. A pair of core reinforcing members presenting terminal ends extend between the first and second header tanks. A least one tab and an opening for receiving the tab are used for connecting the core reinforcing members to the tank caps.

Heat exchanger assembly for a motor vehicle

A heat exchanger includes two parallel tank units forming a fluid space therein, and supporting a core therebetween. The core includes parallel tube passes connected between the tank units, and air centers connected between the tube passes for conductive heat exchange with air flowing therethrough. The header includes tube slots therein for receiving the ends of the tube passes in fluid communication with the fluid space. The tank units are comprised of a separate header and tank. The tank is formed of a U-shaped extrusion with grooves formed in the opposing arms thereof. The header is arcuately shaped and includes side edges parallel to one another to be received within the grooves for connecting the header to the tank.

Heat exchanger header with parallel edges

A heat exchanger apparatus includes a pair of tanks with parallel tube passes and air centers connected therebetween for cooling the engine fluid, such as a coolant, by the air intake stream to the vehicle. The tanks are formed by an extrusion forming three sides thereof and a header is brazed thereto for forming the fluid chamber in the tanks. The extrusion includes a die formed pocket therein to receive the sides and one end of a partition member and the second end of the partition member is curved to abut the header. The curved second end has flanged ears therein that seat in segments of the die formed pocket which are laterally outwardly of spaced sides segments of the pocket to position the partition within the pocket so that an outer surface thereon will be positioned against a header to form a braze seal between the partition and both the header and the extruded tank.

Extruded tank pocket design for separator

A condenser having two piece die formed condenser tube parts that are joined along a beveled outer edge. The tube material is braze cladded on both sides for corrosion resistance and for high quality internal braze bonding of (1) longitudinal tube webs for optimizing burst strength, and (2) the tubes to associated air centers which are not cladded for an economical unit. The tubes can be readily made in a multiport or single port design by die forming the longitudinal webs in each tube part, and at discreet lengths along the tube length to provide a cut off area for sizing the tube and a smooth circumferential area where the tube parts with a beveled outer edge enter the header providing a close fit and high quality brazed joints. This tube design provides material and cost advantages over the conventional extruded tubes or roll formed condenser tubes and is readily fabricated using corrosion resistant alloys providing long service life. The number and spacing of the webs in this construction can be readily made by changing the spacing of the dies for forming the tube parts. The method provided by this invention provides increased output with higher machine speeds as compared to extrusion type processes.

Method of manufacturing a tube for a heat exchanger

A heat exchanger assembly has a pair of spaced extruded tanks and a tube and header subassembly including a pair of header plates on opposite ends of a plurality of spaced parallel tubes. The extruded tanks include stop surfaces thereon for locating the subassembly within the extruded tanks and the extruded tanks further include a pair of seal ribs and a pair of deformable side flanges defining a pocket for receiving flux material to secure the subassembly to the extruded tanks without exposing the flux material to the interior of the extruded tanks.

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Niagara Falls, NY, United States of America

David M Smith