Abstract: A gas-liquid heat exchanger such as a charge air cooler has a core comprising a stack of flat tubes defining liquid coolant flow passages, and a plurality of open-ended gas flow passages between the flat tubes. An endmost gas flow passage is defined between an end plate of the core and an adjacent flat tube, such that the endmost gas flow passage is in contact with only said adjacent one of said flat tubes. A blocking element extends along either the front face or the rear face of the core and at least partly blocking the endmost gas flow passage. Each flat tube may comprise a pair of core plates, at least one including a flap projecting into a gas flow passage and covering a gas bypass channel between the edge of the turbulence-enhancing insert and the sides of a coolant manifold.

Abstract: A gas-liquid heat exchanger such as a charge air cooler has a core comprising a stack of flat tubes defining liquid coolant flow passages, and a plurality of open-ended gas flow passages between the flat tubes. An endmost gas flow passage is defined between an end plate of the core and an adjacent flat tube, such that the endmost gas flow passage is in contact with only said adjacent one of said flat tubes. A blocking element extends along either the front face or the rear face of the core and at least partly blocking the endmost gas flow passage. Each flat tube may comprise a pair of core plates, at least one including a flap projecting into a gas flow passage and covering a gas bypass channel between the edge of the turbulence-enhancing insert and the sides of a coolant manifold.