Each heat exchange tube of a condenser is formed of a first brazing sheet having a core material and a first brazing material covering the core material. The tank body of each header tank is formed of a second brazing sheet having a core material and a third brazing material covering the core material and being lower in flowability than the first brazing material. In a region of a surface of each protrusion portion facing the corresponding heat exchange tube, the region having a predetermined width as measured from the projecting end, the core materials of the two brazing sheets are brazed together by means of the first brazing material. In the region other than the brazed portion, the core materials of the two brazing sheets are brazed together by means of a fillet formed of a mixture of the first and third brazing materials.

An enclosed heat sink with a side wall structure is provided. The side wall structure includes a welding body having a first welding plane and a side wall structure having a second welding plane. The first welding plane and the second welding plane are pressured and welded to each other, such that the welding body and the side wall structure encapsulate a cavity. A width of the second welding plane is smaller than a width between two side surfaces of the side wall structure.

A metal matrix (2) for a heat exchanger (1), comprising a stack of components (4, 5, 6), in particular etched plates or corrugations (4), separator sheets (5) and bars (6), or a combination of the two types of stack, said components (4, 5, 6) being held relative to one another by layers of braze material (3), thereby ensuring the mechanical integrity of the matrix, the matrix including fluid circulation passages (10) within it, each fluid circulation passage (10) having an inner wall provided to fully contain said fluid radially, characterized in that each inner wall is fully covered with a corrosion-resistant coating (7).

Preferred application to heat exchangers based on carbon steel or stainless steel.

A heat exchanger includes a plurality of flat tubes and a coupling header. The flat tubes are disposed in multiple tiers along a predetermined tube tier direction and in multiple rows so as to be adjacent to each other in a tube row direction intersecting the tube tier direction and the longitudinal direction of the flat tubes. The coupling header is formed by joining a first member to a plurality of second members in the tube tier direction. The first member has a plurality of through holes through which pass the first end portions of the flat tubes. The second members when joined to the first member forming a plurality of coupling passages where the first end portions of the flat tubes adjacent to each other in the tube row direction communicate with each other.

One of a first metallic pipe containing a first metal as a main component and a second metallic pipe containing a second metal as a main component includes an expanded-diameter connecting part which is formed at an end part of the one metallic pipe. An inner diameter of the end part is greater than an inner diameter of an adjacent part that is adjacent to the end part. An intermetallic compound layer of the first and second metal is present at an interface of the first and second metal located between a brazing filler metal and the one or the other of the metallic pipes. A thickness of the intermetallic compound layer is configured such that the thickness of an end portion on the side of a base end is smaller than the thickness of an end portion on the side of an open end.

An aluminum alloy brazing sheet has high strength, corrosion resistance and elongation, and includes an aluminum alloy clad material. The material includes a core material, one surface of which is clad with a sacrificial material and an other surface of which is clad with an Al—Si-based or Al—Si—Zn-based brazing filler metal. The core material has a composition containing 1.3 to 2.0% Mn, 0.6 to 1.3% Si, 0.1 to 0.5% Fe and 0.7 to 1.3% Cu, by mass, with the balance Al and impurities. The sacrificial material has a composition containing more than 4.0% to 8.0% Zn, 0.7 to 2.0% Mn, 0.3 to 1.0% Si, 0.3 to 1.0% Fe and 0.05 to 0.3% Ti, by mass, with the balance Al and impurities. At least the core material has a lamellar crystal grain structure. Elongation of material is at least 4% and a tensile strength after brazing is at least 170 MPa.

A metallic tubular member having a closed end member for use in heating, ventilation, and air conditioning (HVAC) systems or refrigeration systems and method of manufacturing are presented. In one instance, the method includes providing a metallic tubular stock member having a first end and a second end, wherein the first end is open and closing the first end of the metallic tubular stock member to form a first closed circular member having an outside diameter D.sub.1; forming a sealing aperture having an outside diameter D.sub.2 through the first closed circular end, wherein D.sub.2 is less than 5 percent of D.sub.1; and applying a heat-based sealing process including a metallic flow into the sealing aperture. Other methods and systems are presented.

A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

A method for manufacturing a heat exchanger includes stacking a plurality of parting sheets, a plurality of lengthwise closure bars, and a plurality of widthwise closure bars to form a rectangular first heat exchanger section. The first heat exchanger section includes at least one widthwise passage extending between a pair of the widthwise closure bars and at least one lengthwise passage extending between a pair of the lengthwise closure bars. The method also includes brazing the rectangular first heat exchanger section together and cutting a first side and a second side of the rectangular first heat exchanger section to give the first heat exchanger section a tapered-trapezoid profile. The method further includes brazing an end of a second heat exchanger section to the first or second side of the first heat exchanger section.

A clad material for a cooler is provided by executing production of a tensile strain of 3 to 10% or rolling at a finish rolling ratio of 10 to 25%, and optionally performing a heat treatment for 1 to 8 hours at a temperature within a range from 150 to 400° C., on a clad raw material having a three layer structure of a core material, a first brazing filler metal layer that covers one side (the surface on the side of a cooling water passage) of this core material, and a second brazing filler metal layer that covers the other side (the surface on the opposite side from the cooling water passage). Specific ranges are prescribed for certain properties before and after brazing.