Curled manifold for evaporator

A method of forming a manifold assembly for a heat exchanger including the steps of:

• forming an upper manifold defining an interior and having an upper top potion defining an upper opening in the center of the upper top portion and an upper bottom portion defining a plurality of spaced upper tube slots;
• dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold;
• and
• joining the partition and the upper manifold.

A heat exchanger assembly comprising:

• an upper manifold defining an interior and having an upper top portion and an upper bottom portion;
• said top portion having a curved shape and an upper opening in the center of said upper top portion;
• a lower manifold being spaced and parallel from said upper manifold;
• said upper bottom portion of said upper manifold defining a plurality of spaced upper tube slots;
• said lower manifold defining a plurality of spaced lower tube slots;
• a plurality of tubes having flat sides and extending between upper and lower tube ends in said upper and lower tube slots and parallel and spaced from one another for defining a plurality of air passages there between;
• said tube slots including a plurality of rows of tube slots one on each side of said central axis;
• said tubes include a plurality of tube rows disposed in said tube slots to define a plurality of passages;
• an air fin disposed between and brazed to said flat sides of said tubes and extending between said upper and lower manifolds for dissipating heat from said tubes;
• said lower manifold defining an interior and having a lower top portion and a lower bottom portion and said top portions of said manifolds having at least one slot;
• at least one separator for insertion into said slots in said top portions to divide the interior of said manifolds into more than two chambers;
• an end cap disposed on each end of said manifolds;
• a partition disposed in said upper manifold to define a plurality of chambers in the interior of said upper manifold;
• said partition having a plurality of spaced and alternating locking tabs for abutting the top portion at the exterior of said upper manifold and a plurality of spaced dimples for abutting the top portion at the interior of said upper manifold to form a snap fit through said opening;
• said dimples having a ramp-like shape when looking at a plane normal to said partition;
• and
• said partition having a plurality of spaced projections and said upper bottom portion having a plurality of spaced upper recesses extending longitudinally straight for accepting said projections;
• and
• said partition defines a plurality of holes for conveying refrigerant through said manifold.