Abstract: The invention is a method for producing a heat exchanger assembly including the steps of extruding a plastic and an adhesive from a co-extrusion die into a plurality of tubes spaced from each other with each tube having an adhesive disposed on its exterior surface. A plurality of corrugated air fins are serially fed into the co-extrusion die and spaced from each other by a predetermined space and ejected between adjacent tubes with the corrugations extending transversely between the tubes. The adhesive is then cured to secure the tubes to the air fins. The method proceeds by cutting the tubes at each predetermined space with a guillotine shear to produce a plurality of unified heat exchanger cores. The ends of the tubes of each core are inserted into tube slots in manifolds, and the tubes and manifolds are adhesively secured together to define a heat exchanger assembly.

Abstract: A chemical reactor is provided that includes: a plurality of tubes having a catalytic reactor substrate therein, each of the tubes having an inlet at one end for receiving a fluid flow and an outlet at an opposing end for discharging fluid flow, and a longitudinal axis parallel to the direction of fluid flow through the tube, the longitudinal axis of each tube being parallel to one another; and a plurality of heat exchange fins disposed on and extending radially from the exterior surface of each tube; the heat exchange fins on each tube independently having a profile along a cross-section perpendicular to the longitudinal axis of each tube, and the tubes being arranged with respect to one another, such that the heat exchange fin profiles together form a tessellated pattern in a plane that is perpendicular to the longitudinal axes of the tubes.

Abstract: A heat exchanger assembly includes a pair of outer headers each defining an outer cavity and a pair of inner headers each defining an inner cavity. Each inner header is disposed in one of the outer headers, and each header defines a plurality of header slots. A plurality of first fluid tubes extend between the outer headers from one of the header slots of each outer header to fluidly interconnect the outer cavities defined by the outer headers and a plurality of second fluid tubes are interleaved with the first refrigerant tubes and extend between the outer headers and through one of the header slots of each outer header and through the associated outer cavities defined by the outer headers and to the one of the header slots of each inner header to fluidly interconnect the inner cavities defined by the inner headers.

Abstract: A textured surface is formed on at least one of a fuel cell mounting plate or fuel cell subassembly to define a joint spacing between these two components. In a preferred embodiment, the textured surface comprises a plurality of dimples coined or otherwise formed in the metal mounting plate. The joint spacing improves the manufacturing and assembly process of the fuel cell cassettes through precise application and control of the brazing process which improves the braze joint strength while reducing material cost.

Abstract: A coupling of a heat exchanger includes a saddle for engaging a cylindrical manifold. The saddle has an arcuate cross-section extending between a first edge and a second edge. The saddle defines an opening and a tubular member extends through the saddle and between a top edge and a bottom edge. A lip extends outward from the top edge and a skirt interconnects the lip to the opening in the saddle. The tubular member is oblong-shaped adjacent the opening of the saddle and the tubular member has an oblong-shaped portion extending from the bottom edge to adjacent the opening in the saddle and terminating at a transition zone. The tubular member has a circular-shaped portion extending from the transition zone to the top edge. The oblong-shaped portion has a shorter dimension in the direction between the first and second edges than the circular shaped portion.

Abstract: A system for adding sulfur to a fuel cell stack, having a reformer adapted to reform a hydrocarbon fuel stream containing sulfur contaminants, thereby providing a reformate stream having sulfur; a sulfur trap fluidly coupled downstream of the reformer for removing sulfur from the reformate stream, thereby providing a desulfurized reformate stream; and a metering device in fluid communication with the reformate stream upstream of the sulfur trap and with the desulfurized reformate stream downstream of the sulfur trap. The metering device is adapted to bypass a portion of the reformate stream to mix with the desulfurized reformate stream, thereby producing a conditioned reformate stream having a predetermined sulfur concentration that gives an acceptable balance of minimal drop in initial power with the desired maximum stability of operation over prolonged periods for the fuel cell stack.

Abstract: An improved LSCF 6428 perovskite material of the type La12zSrx+zCo0.2+aFe0.8+bO3?? wherein x=0.4, z=(0-0.1), a=(0.01-0.04), and b=(0.05-0.15) for use as an SOFC cathode having increased electronic and ionic conductivity. The general formula is similar to the prior art formulae (La0.6Sr0.4)1?zCo0.2Fe0.8O3?? and La0.6Sr0.4Co0.2Fe0.8O3?? but applies the z term to La and Sr independently as well as reducing the overall content of La. Further, by adding a small amount (a) of extra Co ions, catalytic activity, conductivity, and sinterability are further enhanced. Adding small amounts (b) of Fe and/or Fe and Co moderates the thermal expansion coefficient with no adverse effect on crystal structure or fuel cell performance. Improved sinterability, microstructure, and reduced film cracking result in high power density of fuel cells. An inherently low-cost solid state reaction method is described.

Abstract: An air conditioning system of the present invention for an automotive vehicle includes a housing having at least two sections connected by two side by side air passage. A blower device of the air conditioning system discharges air into the housing. An evaporator is disposed in one of the sections for taking heat from the air discharged from the blower device to produce cool air. A heater is disposed in the other section positioned downstream of the evaporator for adding heat to the cool air to produce warm air. First and second sliding valve plates mechanically communicating with a driving mechanism of the present invention are supported by the housing for selectively closing the two side by side air passages thereby regulating air flow of cool and warm air.

Abstract: A battery pack assembly comprising a plurality of battery packs each including a plurality of cells and at least one metering plate for metering the quantity of air flowing respectively through each of the air paths of the battery packs. An inlet metering plate is disposed upstream of the battery packs to meter the uneven flow of cooling air generated by the inlet manifold. The inlet metering plate utilizes a plurality of apertures, which can vary in size and shape, to produce equal streams of cooling air to cool all the battery packs to a substantially uniform temperature. An outlet metering plate can be disposed downstream of the battery packs to meter the flow of outgoing cooling air through the channels of the upper cylindrical sections to produce equal air flow around all of the cells in a stack to cool all of the cells to a substantially uniform temperature.