Abstract: A charge air cooler includes a battery of round tubes that extend between a first header plate and a second header plate arranged at a first end and a second end, respectively, of the charge air cooler. Stresses in corner tubes caused by differential thermal expansion between the tubes and side plates of the charge air cooler are reduced by having a reduced thickness over a portion of the header plates, or by directing a portion of the coolant through the side plates, or both.

Abstract: The present invention provides a charge air cooler for transferring heat between a coolant and charge air including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, a housing connecting the inlet and outlet tanks to define a charge air flow path from the inlet tank to the outlet tank, and a plurality of plate pairs extending into the charge air flow path from, and substantially perpendicular to, a first wall of the housing. Each of the plate pairs can define a multi-pass path for the coolant. Elongated spacers can be positioned between adjacent plate pairs to define the first wall of the housing. The housing can include a second wall opposite the first wall, and the plate pairs can be spaced away from the second wall in order to accommodate differences in thermal expansion between the plate pairs and the housing.

Abstract: A heat exchanger for transferring heat between a first working fluid and a second working fluid, including a pair of spaced apart headers, a number of tubes extending between the pair of headers and providing a flow path for the first working fluid and being positioned along a flow path for the second working fluid, and an insert supportable in one of the tubes and having a fold extending in a direction substantially parallel to the flow path for the first working fluid through the tubes. The fold can define first and second legs of the insert. A dimple can be formed on the first leg and a protrusion can be formed on the second leg opposite to the dimple on the first leg.

Abstract: A heat exchanger for transferring heat between a first working fluid and a second working fluid, including a pair of spaced apart headers, a number of tubes extending between the pair of headers and providing a flow path for the first working fluid and being positioned along a flow path for the second working fluid, and an insert supportable in one of the tubes and having a fold extending in a direction substantially parallel to the flow path for the first working fluid through the tubes. The fold can define first and second legs of the insert. A dimple can be formed on the first leg and a protrusion can be formed on the second leg opposite to the dimple on the first leg.

Abstract: A liquid cooled charge air cooler includes a plurality of pairs of adjacent separator plates supported in parallel spaced relation. The pairs alternatingly define a first set of adjacent pairs in fluid communication with a charge air inlet and a charge air outlet, and a second set of adjacent pairs in fluid communication with a coolant inlet and a coolant outlet. Fins extend between adjacent plates of the first set of adjacent pairs to define a charge air flow path between the charge air inlet and the charge air outlet. A plurality of dams extend between adjacent plates of the second set of adjacent pairs in a select offset configuration to define a multi-pass coolant flow path between the coolant inlet and the coolant outlet. Each dam includes an associated bypass port allowing a portion of coolant to bypass at least a portion of the coolant flow path through the dams.

Abstract: The present invention provides a charge air cooler for transferring heat between a coolant and charge air including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, a housing connecting the inlet and outlet tanks to define a charge air flow path from the inlet tank to the outlet tank, and a plurality of plate pairs extending into the charge air flow path from, and substantially perpendicular to, a first wall of the housing. Each of the plate pairs can define a multi-pass path for the coolant. Elongated spacers can be positioned between adjacent plate pairs to define the first wall of the housing. The housing can include a second wall opposite the first wall, and the plate pairs can be spaced away from the second wall in order to accommodate differences in thermal expansion between the plate pairs and the housing.

Abstract: The present invention provides a heat exchanger for transferring heat between a first working fluid and a second working fluid, including a pair of spaced apart headers, a number of tubes extending between the pair of headers and providing a flow path for the first working fluid and being positioned along a flow path for the second working fluid, and an insert supportable in one of the tubes and having a fold extending in a direction substantially parallel to the flow path for the first working fluid through the tubes. The fold can define first and second legs of the insert. A dimple can be formed on the first leg and a protrusion can be formed on the second leg opposite to the dimple on the first leg.

Abstract: A heat exchanger (24) is provided and includes a heat exchanger core (30), a housing (32), and a seal structure (34). The core (30) has a pair of opposite faces bounded by a periphery (40), and includes a plurality of enclosed flow passages (50) to direct a first fluid through the core (30) and a plurality of open flow passages (52) extending between their opposite faces (36, 38) to direct a second fluid through the core (30). The seal structure (34) is sandwiched between the housing (32) and a majority of the periphery (40) to restrict bypassing of the second fluid around the open flow passages (52).

Abstract: The present invention provides a charge air cooler for transferring heat between a coolant and charge air including a charge air inlet tank, a charge air outlet tank spaced from the inlet tank, and a heat exchange core positioned between the inlet and outlet tanks and including a stack of plate pairs. Each of the plate pairs can define a multi-pass path for the coolant. Elongated spacers can be positioned between adjacent plate pairs and extend between the inlet tank and the outlet tank on opposite sides of the heat exchange core to define flow paths for the charge air through the heat exchange core.

Abstract: Improved fuel cell stacks constructed from a plurality of cells, each comprising a series of interrelated mono and bipolar collector plates (BSPs), which in turn are built up by lamination of a core of related non-conductiveplastic orceramic platelets sandwiched between conductive microscreen platelets of metal or conductive ceramic or plastic, with an electrode membrane (EMA) between adjacent BSPs. The platelets, both metal and plastic of the composite BSPs, are produced from sheet material with through and depth features formed by etching, pressing, stamping, casting, embossing and the like. Adjacent plates, each with correspondingly relieved features form serpentine channels within the resultant monolithic platelet/cell stack for integrated fluid and thermal management. The plastic platelets are particularly useful for PEM fuel cells employing H.sub.2 and Air/O.sub.2 as fuel. The platelets are easily made by printing (embossing) processes, and dies made by photolithographic etching for rapid redesign.