Transpro, Inc.

Marco Lambert

Michael J Kolb

Joseph S JuGer

A heat exchanger comprising a core assembly having a plurality of tubes connected by an array of fins, with ends of the tubes extending from the fin array on at least one side of the core assembly and resilient, polymeric grommets disposed around, the tube ends. The heat exchanger includes a tank portion for receiving fluid entering or leaving the core assembly and a header portion having openings to receive the tube ends and grommets to create a sealed, fluid-tight tube-to-header joint. There is provided a reinforcing member across the opening of the tube ends extending from the tube end opening to the portion of the tube end around which the grommet is disposed without substantially extending into the fin array portion of the core assembly. The header portion comprises a substantially planar base having openings therein with side and end walls extending out of the plane of the base and connected by one or more fluid-tight welds to the tank portion. The side and end walls extend a distance sufficient to dissipate heat generated in making the welds and keep the heat generated from adversely affecting sealing ability of the grommets when the welds are made between the tank and header portion with the tube ends and grommets received in the header portion openings.

Welded heat exchanger with grommet construction

A heat exchanger comprises an as-cast combined header and tank having a header portion integral with a tank portion. The cast header and tank combination has a plurality of openings originally cast in the header portion of the combination and at least one opening originally cast in the tank portion of the combination for passage of coolant into or out of the cast header and tank combination. Tubes are received in and extends through the header portion openings, and resilient grommets seal the tubes to the header portion to prevent leakage around the tubes. In making the heat exchanger, there is provided an inner mold section and outer mold section corresponding respectively to the interior and exterior configurations of a desired combined header and tank having a header portion integral with a tank portion. The inner mold and outer mold sections are connected through the header and tank portion openings to support the inner mold section within the outer mold section and create a space therebetween corresponding to the configuration of the combined header and tank. The space is filled with molten metal and solidified to create the combined cast header and tank having the header portion integral with a tank portion. The outer mold section is removed and the inner mold section is removed from inside the cast header and tank through an opening in the header portion and/or through an opening in the tank portion. Following removal of the mold portions, the method may include inserting a tube from a heat exchanger core into an opening in the cast header portion and securing the tube therein.

Heat exchanger assembly utilizing grommets and integral cast tanks

A method of manufacturing a heat exchanger comprising a core assembly having a plurality of tubes connected by an array of fins, with ends of the tubes extending from the fin array on at least one side of the core assembly and resilient, polymeric grommets disposed around the tube ends. The heat exchanger includes a tank portion for receiving fluid entering or leaving the core assembly and a header portion having openings to receive the tube ends and grommets to create a sealed, fluid-tight tube-to-header joint. There is provided a reinforcing member across the opening of the tube ends extending from the tube end opening to the portion of the tube end around which the grommet is disposed without substantially extending into the fin array portion of the core assembly. The header portion comprises a substantially planar base having openings therein with side and end walls extending out of the plane of the base and connected by one or more fluid-tight welds to the tank portion. The side and end walls extend a distance sufficient to dissipate heat generated in making the welds and keep the heat generated from adversely affecting sealing ability of the grommets when the welds are made between the tank and header portion with the tube ends and grommets received in the header portion openings.

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Vernon, CT, United States of America

Marco Lambert