Heat exchanger assembly utilizing grommets and integral cast tanks

A method of making a heat exchanger comprising the steps of:

• a) providing a combined cast header and tank having a header portion integral with a tank portion, the cast header and tank combination having a plurality of openings originally cast in the header portion of the combination for passage of fluid into or out of the cast header and tank combination;
• b) providing tubes from a heat exchanger core for insertion within the header portion cast openings;
• c) providing resilient grommets having a body portion for extending within the header portion cast openings;
• d) thereafter inserting said grommets into said header portion cast openings;
• and
• e) inserting said tubes into said header portion cast opening and through the grommet body portion to seal said tubes to said header portion cast openings.

A method of making a heat exchanger comprising the steps of:

• a) providing an inner mold section and outer mold section corresponding respectively to interior and exterior configurations of a desired combined cast header and tank having a header portion integral with a tank portion, each of the header and tank portions having at least one opening therein for passage of fluid;
• b) connecting said inner mold and outer mold sections with mold material through both the header and tank portion openings to support said inner mold section within said outer mold section and create a space therebetween corresponding to the desired interior and exterior configurations of said combined header and tank;
• c) filling said space with molten metal and solidifying said molten metal to create a combined cast header and tank having a header portion integral with a tank portion, the cast header and tank combination having at least one opening in the header portion and at least one opening in the tank portion for passage of fluid into or out of the cast header and tank combination;
• d) removing said cast header and tank combination from said outer mold section;
• e) removing said inner mold section from said cast header and tank combination;
• and
• f) inserting a tube from a heat exchanger core into said at least one opening in said cast header portion and securing said tube therein.

A method of making a heat exchanger comprising the steps of:

• a) providing an inner mold section and outer mold section corresponding respectively to interior and exterior configurations of a desired combined cast header and tank having a header portion integral with a tank portion, said header portion having a plurality of openings therein for passage of fluid and said tank portion having an opening therein for passage of fluid;
• b) connecting said inner mold and outer mold sections with mold material through both the header and tank portion openings to support said inner mold section within said outer mold section and create a space therebetween corresponding to the desired interior and exterior configurations of said combined header and tank;
• c) filling said space with molten metal and solidifying said molten metal to create a combined cast header and tank having a header portion integral with a tank portion, the cast header and tank combination having a plurality of openings in the header portion for passage of fluid into or out of the cast header and tank combination;
• d) removing said cast header and tank combination from said outer mold section;
• e) removing said inner mold section from said cast header and tank combination;
• and
• f) inserting tubes from a heat exchanger core into said openings in said cast header portion and securing said tubes therein.