Heat exchangers and methods for assembling a heat exchanger are described, such as for example a round tube heat exchanger, which may be a fin and tube heat exchanger, and which may be used for example in a heating, ventilation, and air conditioning system (HVAC) system and/or unit thereof. The heat exchanger includes aluminum tubes mechanically rolled into an aluminum tube support and the tubes are fluidically sealed with the tube support. The aluminum tube support including the aluminum tubes rolled therein is assembled to a fluid manifold configured to allow fluid flow through the heat exchanger and into and/or out of the heat exchanger.

A method and system are described for a refrigerant distributor, and for attaching the distributor tubes to an evaporator coil. A short tube can inserted into the bell end of a tube and the hell end can he crimped around the short tube to lock it into place. The short tube preferably has a bead or widened shaft around which to crimp the bell. The disclosure is particularly beneficial for aluminum based components because aluminum is more susceptible to blockages or leaking due to problems from brazing.

In one aspect, a tubular membrane assembly is provided for a heat exchanger. The tubular membrane assembly includes a header having a header body, a tubular membrane, and a fitting connecting the tubular membrane to the header body. The fitting is configured to form a fluid tight connection between the fitting and the tubular membrane. The tubular membrane assembly further includes potting of the header keeping the tubular membrane connected to the fitting.

Heat exchangers and methods for assembling a heat exchanger are described, such as for example a round tube heat exchanger, which may be a fin and tube heat exchanger, and which may be used for example in a heating, ventilation, and air conditioning system (HVAC) system and/or unit thereof. The heat exchanger includes aluminum tubes mechanically rolled into an aluminum tube support and the tubes are fluidically sealed with the tube support. The aluminum tube support including the aluminum tubes rolled therein is assembled to a fluid manifold configured to allow fluid flow through the heat exchanger and into and/or out of the heat exchanger.

A method and system are described for a refrigerant distributor, and for attaching the distributor tubes to an evaporator coil. A short tube can inserted into the bell end of a tube and the bell end can be crimped around the short tube to lock it into place. The short tube preferably has a bead or widened shaft around which to crimp the bell. The disclosure is particularly beneficial for aluminum based components because aluminum is more susceptible to blockages or leaking due to problems from brazing.

Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes fabricating an HX tube by at least partially forming the elongated tube body utilizing a cold spray process during which a metallic feedstock powder is deposited over a removable mandrel. The HX tube is separated from the removable mandrel at some juncture following cold spray deposition of the tube body.

Methods are disclosed for fabricating heat exchangers and Heat Exchanger (HX) tubes, as are heat exchangers fabricated in accordance with such methods. In embodiments, the method includes the steps or processes of obtaining a Non-Equilibrium Alloy (NEA) feedstock powder comprised of an alloy matrix throughout which at least one minority constituent is dispersed. The first minority constituent precipitates from the alloy matrix when the NEA feedstock powder is exposed to temperatures exceeding a critical temperature threshold (T.sub.CRITICAL) for a predetermined time period. A cold spray process is carried-out to at least partially form the HX tubes from the NEA feedstock powder; and the HX tubes are subsequently installed in the heat exchanger. The HX tubes are exposed to a maximum temperature (T.sub.SPRAY_MAX) during the cold spray process, which is maintained below T.sub.CRITICAL to substantially preserve the non-equilibrium state of the NEA feedstock powder through cold spray deposition.

To provide a structure of a heat exchanger core that enables the outer periphery of an stacked body 8 including an assembly of flat tubes to be held in a previously fastened state and is excellent in mass-productivity, external frame portions of a pair of frame bodies are fitted onto both ends of a bulging portion of the stacked body of the flat tubes, and, in the state where the stacked body is restrained, a casing is additionally fitted onto the outer periphery of the stacked body.

A heat exchanger manifold for use in a heat exchanger having a plurality of microtubes includes a receiving component for supporting and forming a seal about each of the plurality of microtubes and a circuiting component having at least one recessed channel for defining an enclosed flow configuration of a fluid of the heat exchanger. The receiving component is joined and sealed to the circuiting component such that an internal flow passage of the plurality of microtubes is arranged in fluid communication with the at least one recessed channel.

A heat exchanger including a header having a plurality of header openings with rigid tubes that may be made of plastic are inserted in the openings. The tubes are sealed to the header to prevent leakage between the header and the tubes to prevent water and air leakage between the wet, scavenger air stream flowing through the tubes and a dry air stream flowing around the tubes. A method of making the heat exchanger includes providing the openings with a flange and uses an interference fit between the rigid heat exchange tubes and the header openings. A self-leveling sealant may be used to seal the heat exchanger tubes to the header using, for example, a paint roller and/or a paint sprayer.