Abstract: An exemplary heat exchanger includes a heat exchanger core having a core side fluid space and a cover plate and a substantially U-shaped wall fitted at one end with an inlet header and, at an opposing end, with an outlet header, which in combination with the cover plate, define a shell side fluid space. In this example, the cover plate forms two seals with two opposing sides of the U-shaped wall, forms a seal with the inlet header and forms a seal with the outlet header. Such a heat exchange may be suitable for use as an EGR cooler. Other exemplary devices, methods and systems are disclosed.

Abstract: Apparatus and method for cooling heated fluids, such as exhaust gases, flowing through a heat exchanger comprising one or more exhaust plenums and one or more coolant plenums, and providing increased coolant velocity in that portion of the coolant plenums contacting the inlet portion of the exhaust plenums. Local increased coolant velocity is provided by any means, including decreasing the area-in-flow of the coolant plenums wherein increased velocity is desired, shaping or baffling either or both inlet or outlet coolant tanks in fluidic contact with coolant plenums wherein increased velocity is desired, or a combination thereof.

Abstract: A diffuser comprising an inlet passage, an outwardly diverging sidewall, and an outlet. The inlet, outwardly diverging sidewall and outlet each have an inside surface that defines an interior through which a gas or fluid passes in a flow direction from the inlet to the outlet. Wherein at least a region of the inside surface includes a plurality of individual surface features that are configured to reduce or eliminate unwanted boundary layer separation of gas or fluid that passes thereover.

Abstract: An exemplary heat exchanger includes a heat exchanger core having a core side fluid space and a cover plate and a substantially U-shaped wall fitted at one end with an inlet header and, at an opposing end, with an outlet header, which in combination with the cover plate, define a shell side fluid space. In this example, the cover plate forms two seals with two opposing sides of the U-shaped wall, forms a seal with the inlet header and forms a seal with the outlet header Such a heat exchange may be suitable for use as an EGR cooler. Other exemplary devices, methods and systems are disclosed.

Abstract: An exemplary heat exchanger, suitable for use in exhaust gas recirculation to cool exhaust gas, includes a cover plate having a plurality of openings, an upper plate having a plurality of openings, a lower plate having a plurality of openings and a bottom plate where seals exist between various plates to form at least one gas flow space and at least one liquid flow space. Various other exemplary heat exchanger configurations are also disclosed.

Abstract: An exhaust gas cooler comprising an inlet chamber shaped to restrict exhaust gas flow to certain exhaust gas passages provided therein is disclosed. The inlet chamber may comprise a flow deflector which deflects a proportion of exhaust gas into, for example, the upper exhaust gas cooling passages thus restricting flow to lower exhaust gas cooling passages. In one embodiment the flow deflector is rotatably mounted and can also function as a bypass valve. Alternatively apertures provided within plates which can collectively define the inlet chamber may be of a differing size to restrict exhaust gas flow to certain exhaust gas cooling passages. A more balanced flow through the various exhaust gas cooling passages results increasing heat-exchange efficiency of the exhaust gas cooler.

Abstract: A diverter, apparatus and method of bypassing an exhaust gas recirculation cooler in order to selectively cool recirculated exhaust gas is disclosed. The diverter relies on the Coanda effect to direct the exhaust gas flow to the cooler or to a bypass around the cooler and thus preferred embodiments do not require a valve to be provided in the exhaust gas flow for this purpose. This simplifies the assembly of the diverter and apparatus and provides for a more reliable diverter compared to certain known systems.

Abstract: Heat exchangers, constructed in accordance with principles of this invention, comprise a plurality of first passages, for transporting a first fluid or gas therethrough, and one or more second passages for transporting a second fluid or gas therethrough. The second passages are positioned adjacent to the first passages to permit a desired transfer of thermal energy from the first passages to the second passages. At least one manifold is placed in communication with one of the first or second passages. The manifold includes an opening disposed therethrough for receiving or dispensing the first or second fluid or gas to or from the first or second passages. The heat exchanger includes a flow director disposed therein for diverting or distributing the flow of first or second fluid or gas in a manner different from a natural fluid or gas flow within the heat exchanger.

Abstract: A heat exchanger includes a core with a plurality of passages arranged therein each having an opening positioned adjacent an end portion of the core. A manifold is positioned adjacent the core end portion and includes an inlet and an outlet opening. The manifold includes a divider wall that extends internally therein and that forms separated inlet and outlet passages that are in communication with the respective inlet and outlet openings. The heat exchanger includes a metallic seal interposed between the divider wall and the core to provide a seal therebetween. The seal is constructed to impose a biasing force between the divider wall and the core to provide the desired seal, thereby minimizing or eliminating any unwanted bypass of fluid or gas within the manifold during heat exchanger operation and increasing heat exchanger operating efficiency.

Abstract: An EGR cooler comprises a cooling core having a plurality of passages for accommodating the flow of exhaust gas therethrough, an exhaust gas inlet chamber connected to the cooling core, for receiving exhaust gas from an internal combustion engine and passing the exhaust gas to the cooling core, and an exhaust gas outlet chamber separate from the exhaust gas inlet chamber and connected to the cooling core for receiving exhaust gas from the core. The cooler further includes means for permitting the controlled passage of exhaust gas from the exhaust gas inlet chamber to the exhaust gas outlet chamber without passing through the cooling core, said means being positioned upstream from the exhaust gas outlet chamber. Configured in this manner, the EGR cooler permits the mixing of cooled exhaust gas with uncooled exhaust to provide a desired exiting gas temperature that is below an exhaust gas dew point.

Abstract: A heat exchanger tube is provided that includes an inner diameter, an outer diameter and a longitudinal axis. The heat exchanger includes at least two spiral upsets protruding from the inner diameter of the tube and spiraling around the longitudinal axis of a length of the tube. The at least two spiral upsets include a first spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis, and a second spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis. In one embodiment, the angle of the first spiral upset with respect to the longitudinal axis is approximately equal to the angle of the second spiral upset with respect to the longitudinal axis, such that the first and second spiral upsets are approximately parallel.

Abstract: Heat exchangers of this invention include a shell having an inner chamber defined by an inside wall surface, and having at least one opening adjacent an end of the shell. A tube bundle comprising a plurality of assembled together tubes are disposed within the inner chamber. A header plate is attached to the tubes and is positioned adjacent an end of the tube bundle. The header plate includes an outside diameter that fits within the shell inside wall surface to provide a nested attachment junction therebetween. The header plate and shell are fixedly connected to one another by use of a braze joint formed by the placement of brazing material between the interfacing header plate and the shell surface sections. A tank is attached to the shell adjacent the shell end.

Abstract: Exemplary methods, devices and/or system for facilitating transfer of heat energy between a gas and a cooler liquid. An exemplary heat exchanger is suitable for use as an EGR cooler.

Abstract: Heat exchangers, constructed in accordance with principles of this invention, comprise a plurality of first passages, for transporting a first fluid or gas therethrough, and one or more second passages for transporting a second fluid or gas therethrough. The second passages are positioned adjacent to the first passages to permit a desired transfer of thermal energy from the first passages to the second passages. At least one manifold is placed in communication with one of the first or second passages. The manifold includes an opening disposed therethrough for receiving or dispensing the first or second fluid or gas to or from the first or second passages. The heat exchanger includes a flow director disposed therein for diverting or distributing the flow of first or second fluid or gas in a manner different from a natural fluid or gas flow within the heat exchanger.

Abstract: A heat exchanger tube is provided that includes an inner diameter, an outer diameter and a longitudinal axis. The heat exchanger includes at least two spiral upsets protruding from the inner diameter of the tube and spiraling around the longitudinal axis of a length of the tube. The at least two spiral upsets include a first spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis, and a second spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis. In one embodiment, the angle of the first spiral upset with respect to the longitudinal axis is approximately equal to the angle of the second spiral upset with respect to the longitudinal axis, such that the first and second spiral upsets are approximately parallel.

Abstract: There is provided a heat exchanger, such as an exhaust gas cooler, that has a removable core at least partially disposed in a shell. Tubes extending through the shell fluidly connect tanks at both ends of the shell so that thermal energy can be transferred between a first fluid in the shell and a second fluid in the tubes. At least one of the tanks is defined partially by a tube sheet, and the tank is structured to be moved axially through the shell in a direction toward the opposite tank and removed from the shell with the tubes. A sealing member is disposed between the movable tank and the shell to prevent fluid from flowing therebetween.

Abstract: An EGR cooler comprises a cooling core having a plurality of passages for accommodating the flow of exhaust gas therethrough, an exhaust gas inlet chamber connected to the cooling core, for receiving exhaust gas from an internal combustion engine and passing the exhaust gas to the cooling core, and an exhaust gas outlet chamber separate from the exhaust gas inlet chamber and connected to the cooling core for receiving exhaust gas from the core. The cooler further includes means for permitting the controlled passage of exhaust gas from the exhaust gas inlet chamber to the exhaust gas outlet chamber without passing through the cooling core, said means being positioned upstream from the exhaust gas outlet chamber. Configured in this manner, the EGR cooler permits the mixing of cooled exhaust gas with uncooled exhaust to provide a desired exiting gas temperature that is below an exhaust gas dew point.