Importance

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Abstract

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.

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First Claim