An integrally-formed liquid collecting box structure and a method for manufacturing the same are presented. The integrally-formed liquid collecting box structure includes an integrally-formed liquid collecting box, a screw, and a leak-proof sealing ring. The leak-proof sealing ring is located between a nut portion of the screw and an inner end face of a stepped hole. The screw is screwed into an internal threaded hole. When the screw is tightened, the nut portion squeezes the leak-proof sealing ring so that the leak-proof sealing ring is deformed and clamped between the nut portion and the inner end face of the stepped hole, so as to prevent leakage.

A heat exchanger includes an inlet tank (10a) connected to and in fluid communication with an inlet pipe (12a) for ingress of a coolant therein, an outlet tank (10b) connected to and in fluid communication with an outlet pipe (12b) for egress of coolant there from. The heat exchanger further includes heat exchange tubes (20) and a tubular element (30) to configure fluid communication between the inlet tank (10a) and the outlet tank (10b). A first side of the outlet tank (10b) is complimentary to and connected to the outlet pipe (12b) and an opposite second side of the outlet tank (10b) is complimentary to and aligned with the tubular element (30). The tubular element (30) and the outlet pipe (12b) are of different cross sections, wherein shape of the outlet tank (10b) transforms smoothly between those cross sections along fluid path.

A method of making a heat exchanger that includes sealing tubes to header slots and brazing the tubes to the header slots. The method further includes coupling a cover to the header to cover a liquid-side surface of the header and to cover ends of the tubes, and applying flux to an air-side surface of the header and to the tubes. Coupling the cover to the header is performed after sealing the tubes to the header slots and coupling the cover to the header is performed before applying flux to the air-side surface of the header and to the tubes. Applying flux is performed before brazing each of the tubes to the header slots and sealing each of the tubes to the header slot includes sealing a perimeter of each of the tubes to the header slot.

A heater core assembly (10) comprising: a core (12) comprising a plurality of micro-tubes (13A, 13B), the plurality of micro-tubes (13A, 13B) being stacked in horizontal rows (15) between at least two headers (18) by inserting ends of each of the micro-tubes (13A,13B) into slots (42A, 42B) provided in the headers (18); a partition plate (30) disposed vertically in each of header (18) to define two vertical chambers (18A, 18B); wherein each of the horizontal rows (15) include at least one first micro-tube (13A) inserted in the first chamber (18A) and at least second micro-tube (13B) inserted in the second chamber (18B) to enable flow of the coolant in the core assembly (10).

A method of making a heat exchanger that includes sealing tubes to header slots and brazing the tubes to the header slots. The method further includes coupling a cover to the header to cover a liquid-side surface of the header and to cover ends of the tubes, and applying flux to an air-side surface of the header and to the tubes. Coupling the cover to the header is performed after sealing the tubes to the header slots and coupling the cover to the header is performed before applying flux to the air-side surface of the header and to the tubes. Applying flux is performed before brazing each of the tubes to the header slots and sealing each of the tubes to the header slot includes sealing a perimeter of each of the tubes to the header slot.

A heat exchanger includes tubes, a pair of tanks, and a connector. The tubes are stacked with each other in a stacking direction. The pair of tanks are disposed at both ends of the tubes and a longitudinal direction of the tanks extends along the stacking direction. At least one of the tanks is a connecting tank. The connector is disposed in a side portion of the connecting tank to fluidly connect a pipe to the connecting tank. The connecting tank has a tubular shape and includes a flat surface on the side portion. The connector includes a facing surface facing the flat surface. The facing surface is joined to the flat surface such that at least a portion of the facing surface extends beyond the flat surface in a lateral direction of the connecting tank.

A heat exchanger is arranged at one side in a predetermined direction with respect to a wall body having a ventilation opening. A core portion includes a plurality of tubes in which a heat medium flows to exchange heat with air having passed through the ventilation opening. A first header tank is connected to one ends of the plurality of tubes, and is provided with an inflow port from which the heat medium flows into the first header tank. The other ends of the plurality of tubes are connected to a second header tank, and the heat medium flowing through the tubes collects into the second header tank. The core portion has an opening overlapping range that overlaps with the ventilation opening at the one side in the predetermined direction, and a large amount of the heat medium flows unevenly into the opening overlapping range of the entire core portion.

A stiffener for a heat exchanger includes a top plate and at least two legs extending from opposing sides of the top plate. Each of the at least two legs includes a bent portion, an angled portion, and a straight portion. The bent portion attaches the leg to the top plate. The angled portion increases a width of the stiffener from a width of the top plate. The straight portion extends perpendicular to a plane of the top plate.

A cap (20) for a header box of a heat exchanger (1), in particular for a motor vehicle, in particular a radiator, is disclosed. This cap includes a head (21), a shank (22) comprising at least one mounting thread (23), this shank being between the head and a free end of the cap, a retaining lug (30), in particular elastically deformable, arranged to retain the cap in an opening (10) of the header box in an intermediate position of the cap, in which position the cap leaves a clear passage while being retained in the opening, this retaining lug being formed on the shank.

A collector plate for a motor vehicle heat exchanger may include a first receiving zone for tubes of a first tube bundle of a heat exchanger. The collector plate may include a second receiving zone for tubes of a second tube bundle of a heat exchanger and a groove extending between the first and second receiving zones. The collector plate may be thinner in a region of the groove. Further, the collector plate may have a channel reducing the thickness of the collector plate from a first face of the collector plate and opposing a second face of the collector plate including the groove.