A method includes providing a first metal sheet and a second metal sheet, printing a plurality of channels on the first metal sheet, bonding the first metal sheet and the second metal sheet to each other to obtain a fin body, bending a first portion of the fin body to be transverse to a second portion of the fin body, separating the first metal sheet and the second metal sheet from each other to form the plurality of channels, introducing working fluid in the plurality of channels, and sealing the first metal sheet and the second metal sheet.

In a heat exchanger, each of a plurality of heat exchange members includes: a flat pipe; and a heat transfer plate integrated with the flat pipe along a longitudinal direction of the flat pipe. A width direction of each of the flat pipes intersects with a direction in which the plurality of heat exchange members are arranged side by side. Each of the heat transfer plates includes an extending portion extending outward in the width direction of each of the flat pipes from at least one of one end of a corresponding one of the flat pipes in the width direction and another end of the corresponding one of the flat pipes in the width direction. Each of the flat pipes has one or more flat pipe bent portions, each forming a groove extending along the longitudinal direction of the flat pipes.

A collector tube for a heat exchanger, which may have at least one flat tube, may include at least one recess, through which a separator may be inserted into the collector tube in an insertion position. The separator may have a separating wall comprising a separating wall thickness, wherein a clearance fit may be present between the separating wall and the recess in response to the insertion of the separator. The separating wall may provide at least one elevation to attain an increase of the separating wall thickness in a subarea of the separator. In the insertion position of the separator, the at least one elevation may be arranged in an area of the recess. In the insertion position, a press fit may be present between the at least one elevation and the recess.

A heat exchanger assembly includes a first member defining fluid passages therein for a first heat exchanger fluid. A second member defines fluid passages therein for a second heat exchanger fluid. The second member is engaged to the second member with an interference fit. A method of assembling a heat exchanger includes thermally resizing at least one of a first heat exchanger member and a second heat exchanger member and assembling the second heat exchanger member to the first heat exchanger member. The method includes thermally equalizing the first and second heat exchanger members to engage the second heat exchanger member to the first heat exchanger member with an interference fit.

The present invention reduces and mitigates thermal stress generated at joint portions between a header plate and a flat tube of a heat exchanger. In a direction of a vertical center axis passing the center of the inside of a flat tube, positions of first brazing parts are set to be closer to the center of the flat tube in the direction of the vertical center axis than positions of edge brazing parts. Accordingly, the thermal stress concentrated at the joint portions between short sides of the flat tube and the header plate is dispersed to other portions.

A compact heat exchanger unit within an air conditioning apparatus for a vehicle, and a condenser region for the condensation of refrigerant is formed as a heat exchanging surface, and a high-pressure-refrigerant collector region as a refrigerant collector is formed in the integrated form as a plate packet of a heat exchanger within a plate heat exchanger.

Iron-based braze filler alloys having unexpectedly narrow melting temperature ranges, low solidus and low liquidus temperatures, as determined by Differential Scanning calorimetry (DSC), while exhibiting high temperature corrosion resistance, good wetting, and spreading, without deleterious significant boride formation into the base metal, and that can be brazed below 1,100 C contains a) nickel in an amount of from 0% to 35% by weight, b) chromium in an amount of from 0% to 25% by weight, c) silicon in an amount of from 4% to 9% by weight, d) phosphorous in an amount of from 5% to 11% by weight, e) boron in an amount of from 0% to 1% by weight, and f) the balance being iron, the percentages of a) to f) adding up to 100% by weight. The braze filler alloys or metals have sufficient high temperature corrosion resistance to withstand high temperature conditions of Exhaust Gas Recirculation Coolers.

A header for a heat exchanger includes a first and a second cylindrical fluid manifold extending in parallel. Each of the first and second manifolds have tube slots that extend through an arcuate wall section of the manifold. A thickened wall section of the header having a generally triangular wall section is bounded by the first and second fluid manifolds and by a planar outer surface of the header. An aperture extends through the thickened wall section to provide a fluid communication pathway between the first and second cylindrical fluid manifolds.

A flexible manifold adapted for use on a plate-fin heat exchanger core, the flexible manifold including a plurality of individual layers configured to be metallurgically joined to respective ones of a plurality of layers of the plate-fin heat exchanger core, and further including a first end with at least one port adapted to receive or discharge a medium, a second end distal from the first end, adapted to transfer the medium to or from the plurality of individual layers, a plurality of horizontal guide vanes defining the plurality of individual layers, and a plurality vertical members positioned within each of the individual layers. The flexible manifold is configured to be mechanically and thermally compliant, and can be metallurgically joined to the heat exchanger core by brazing or welding.

A coldplate assembly includes a plurality of leak-tight conduit modules provided between a base and a cover to couple a first manifold cavity to a second manifold cavity. Each leak-tight conduit module includes a heat conducting structure and is pre-constructed and pre-tested prior to integration into the coldplate assembly. Each leak-tight conduit module is sealed only near the ends of the module that are disposed in the respective manifold cavity.