Abstract: A heat exchanger (10) is provided and in a highly preferred form is an EGR cooler (52) having first and second passes (56A,56B) that are connected to an inlet/outlet manifold (70) by a pair of corresponding thermal expansion joints (87,93) to allow differential thermal expansion between the various structural components of the heat exchanger (10).

Abstract: A heat exchanger including a first header, a second header, and a third header. The third header includes a first plate including a generally planar face and a second plate including a generally planar face parallel to the planar face of the first plate and joined to the planar face of the first plate. The second plate includes an arcuate recess that extends from the planar face of the second plate to at least partially define a flow conduit between a first tube and a second tube. The arcuate recess has a radius of curvature measured from an axis generally parallel to the planar faces of the first and the second plates, and the axis is located within a first plane generally parallel to and midway between first and second opposing flat broad sides of the first tube and the second tube.

Abstract: A fuel cell system includes a plurality of fuel cells arranged into a stack. A combustor receives a cathode exhaust flow from the fuel cell cathodes and a flow of fuel. The fuel is oxidized in the combustor by the cathode exhaust to produce a mixed exhaust flow. A cathode air flow path extends between a fresh air source and the fuel cell cathodes. An air preheater is arranged along the cathode air flow path, cathode air passing through the air preheater being heated therein by a flow of uncombusted anode exhaust from the fuel cell anodes. A cathode recuperator is arranged along the cathode air flow path, cathode air passing through the cathode recuperator being heated therein by the mixed exhaust flow. Water passing through a vaporizer is converted to steam by heat from the mixed exhaust flow and directed from the vaporizer to the fuel cell anodes.

Abstract: A number of flat tubes, flat tube heat exchangers, and methods of manufacturing both are described and illustrated. The flat tubes can be constructed of one, two, or more pieces of sheet material. A profiled insert integral with the flat tube or constructed from another sheet of material can be used to define multiple flow channels through the flat tube. The flat tubes can be constructed of relatively thin material, and can be reinforced with folds of the flat tube material and/or of an insert in areas subject to higher pressure and thermal stresses. Also, the relatively thin flat tube material can have a corrosion layer enabling the material to resist failure due to corrosion. Heat exchangers having such flat tubes connected to collection tubes are also disclosed, as are manners in which such tubes can be provided with fins.

Abstract: A heat exchanger including a tank with first and second ends defining a length and a cross-sectional area transverse to the length. An inlet orifice defined at the first end through which fluid flows in a first direction into the tank, the inlet orifice having a cross-sectional area transverse to the first direction. A voluminous region defined by boundaries which extend generally linearly from the circumference of the cross-sectional area of the inlet orifice to the circumference of the cross-sectional area of the tank. A plurality of conduits providing an outlet for fluid flow from the tank in a second flow direction at a non-parallel angle to the first flow direction. A flow diverter positioned within the voluminous region to direct a portion of fluid flow out of the region and distribute the total volume of fluid flow from the inlet substantially uniformly between the plurality of conduits.

Abstract: A flat tube for use with a heat exchanger. The flat tube including wide sides, narrow sides, an inner insert, a wall that at least partially forms the wide sides and the narrow sides, and the wall is configured to be produced from a punched-out blank. The flat tube further includes an introduction bevel in order to facilitate introduction of the inner insert. The introduction bevel includes at least two bent-down projections at an end of the flat tube. The at least two projections extend over portions of at least one of the wide sides and the narrow sides, and it being possible for the at least two projections to be separated off after the introduction of the inner insert.

Abstract: A fuel cell system (1) is provided and includes a fuel cell stack (3), a cathode recuperator heat exchanger (33) adapted to heat an air inlet stream using heat from a fuel cell stack cathode exhaust stream, and an air preheater heat exchanger (39) which is adapted to heat the air inlet stream using heat from a fuel cell stack anode exhaust stream.

Abstract: A number of flat tubes, flat tube heat exchangers, and methods of manufacturing both are described and illustrated. The flat tubes can be constructed of one, two, or more pieces of sheet material. A profiled insert integral with the flat tube or constructed from another sheet of material can be used to define multiple flow channels through the flat tube. The flat tubes can be constructed of relatively thin material, and can be reinforced with folds of the flat tube material and/or of an insert in areas subject to higher pressure and thermal stresses. Also, the relatively thin flat tube material can have a corrosion layer enabling the material to resist failure due to corrosion. Heat exchangers having such flat tubes connected to collection tubes are also disclosed, as are manners in which such tubes can be provided with fins.

Abstract: The present invention provides an exhaust gas recirculation cooler for transferring heat from engine exhaust to coolant including a pair of spaced apart headers, a tube body extending between the pair of headers and positioned along a flow path for the coolant and at least partially defining a flow path for the engine exhaust along a length of the tube between the pair of headers, and a corrugated insert supported in an interior of the tube and having a height in a direction of a plurality of corrugations and a width between about 8.6 and about 13.5 times the height. The width can be substantially perpendicular to the length of the tube and can be substantially perpendicular to the height of the insert.

Abstract: A method for producing tubes for use in a heat exchanger that includes providing first and second metallic strips on a rolling mill train with predetermined breaking points using a device, deforming the strips to form the a tube, separating individual tubes from the tube at the predetermined breaking points, sensing positions of the predetermined breaking points in the strips using a sensing element which the strips pass through, transmitting signals relating to sensed positions of the predetermined breaking points of the strips to a computer, comparing the positions of the predetermined breaking points in the first and the second strips using the computer on the basis of the signals transmitted, and sending signals to the device using the computer which lead to the alignment of the positions of the predetermined breaking points in the first and the second strips.

Abstract: An evaporative heat exchanger includes first and second stacked plates forming a first fluid flow path between a first end and a second end. The first stacked plate defines a plane. Third and fourth stacked plates define a second fluid flow path. A fluid flow plate is positioned between the first and second stacked plates, and has a plurality of flow channels extending substantially parallel to the plane between the first end and the second end. At least one of the first and second stacked plates defines slots that form a portion of the first fluid flow path so that fluid flowing along the first fluid flow path flows along the flow channels in the first direction, then flows along at least one of the slots, then flows into adjacent flow channels and then along the adjacent flow channels in a second direction parallel to the first direction.

Abstract: A heat exchanger is provided to efficiently transfer heat between air and a flow of refrigerant in a reversing air-sourced heat pump system. When the system is operating in heat pump mode, a flow of air is directed through the heat exchanger and is heated by the refrigerant. A portion of the flow of air is used to de-superheat the refrigerant in a first section of the heat exchanger, and is prevented from re-heating the sub-cooled refrigerant in another section of the heat exchanger after the remaining air has been heated by the refrigerant. The same heat exchanger can be used to cool a flow of air using expanded refrigerant when the system is operating in an air conditioning (cooling) mode.

Abstract: A fuel cell system includes a plurality of solid oxide fuel cells arranged in a fuel cell stack, an integrated heat exchanger/reformer operable to partially reform an anode feed prior to entry into the fuel cell stack, an anode tailgas oxidizer, and an offgas flow path extending away from an anode side of the fuel cell stack and having a first branch to selectively combine offgas from the anode side of the fuel cell stack with fuel from a fuel source to comprise the anode feed to the fuel cell stack and a second branch to supply offgas from the anode side of the fuel cell stack to the anode tailgas oxidizer. The integrated heat exchanger/reformer transfers heat from the oxidized offgas from the anode tailgas oxidizer to the anode feed before the anode feed enters the anode side of the fuel cell stack. The offgas from the anode tailgas oxidizer provides the sole heat source for the anode feed traveling through the integrated heat exchanger/reformer.

Abstract: A heat exchanger and a method are provided to vaporize a working fluid using a heat sourcing fluid. The heat exchanger includes a first section, a second section, and a third section. A first portion of the heat sourcing fluid passes through the first section, in counter-flow with the working fluid. A second portion of the heat sourcing fluid passes through the second section, in co-flow with the working fluid. Both the first and second portions pass through the third section, in overall counter-flow with the working fluid. The working fluid passes sequentially through the third section, the first section, and the second section. The heat exchanger and/or the method may be used in a Rankine cycle for waste heat recovery or in a refrigerant cycle.

Abstract: The invention relates to a method for producing slots (11) in a tube wall (10), wherein a single die plate (2) provided with notches (20) is pushed into the tube (1) and punches (5) arranged in a row pierce the tube wall from the outside and in the process produce the slots (10), whereupon the die plate (2) is rotated about its longitudinal axis out of a working position and into a withdrawal position and is pulled out of the tube (1). Economical production of the slots in tubes having different cross-sectional shapes is achieved according to the invention in that during the slotting operation the tube wall (30) is gripped from the outside and held and is stabilized from the inside against two opposing support strips (25) by way of the die plate (2).

Abstract: A system and method for producing flat tubes is described and illustrated. The flat tubes can be produced from at least one strip of endless band material having at least one wall part and an inner part formed with corrugations on a roller train provided with roller pairs, with the strip running in a longitudinal direction through the rollers and being shaped. The inner part of the flat tube can be formed with corrugations placed between the shaped wall parts, after which the closure of the flat tube is carried out. Production of the flat tubes can include forming spaced apart band thinning lines running in the longitudinal direction of the strip, and forming corrugation peaks and corrugation troughs at the band thinning lines.

Abstract: An evaporative heat exchanger including a plurality of parallel flow passages extending through the heat exchanger and together defining a first fluid flow path, and a plurality of substantially parallel stacked plates interleaved with the parallel flow passages. Each plate can have first, second, and third sets of flow channels, a first collection manifold adjacent to an end of the plate and connecting the first and second passes, and a second collection manifold. The second collection manifold can intersect the second set of flow channels and at least some of the third set of flow channels. The plate separates the first set of flow channels from the second collection manifold.

Abstract: The invention relates to a heat exchanger (e.g., a charge air cooler) having a cooling body composed of flat tubes arranged at intervals and having corrugated fins positioned in the intervals. The charge air in the flat tubes can be cooled by cooling air flowing through the corrugated fins. The heat exchanger can include a flow connector and an integrated pre-cooler in which a medium, for example charge air, is cooled by means of a coolant. The pre-cooler/post cooler can be integrated into a section of the cooling body. A flow connector composed of at least two tubular parts which can be plugged one into the other, locked and sealed, can include a partitioning wall extending in one of the parts. At least one inlet connection and/or at least one outlet connection can be arranged on one or the other of the parts.

Abstract: The invention relates to a cooling fluid cooler for motor vehicles having a soldered cooling network (1) made of flat tubes (101) and ribs (102), produced from very thin aluminum sheets (a, b, c), and having header or loop-around chambers (3) at the ends of the flat tubes (101) for the cooling fluid flowing in the flat tubes (101), said chambers being cooled by cooling air flowing through the ribs (102). The cooling fluid cooler has exceptional cooling power and a light weight. This is achieved according to the invention in that each flat tube (101) is made of at least two formed sheet metal strips (a, b, c), wherein at least the one sheet metal strip (a, b) forms the wall of the flat tube and the other sheet metal strip forms a wavy internal insert (c) forming channels (10) in the same, and that the ratio of the constriction factor on the cooling fluid side to the constriction factor on the cooling air side is approximately in the range of 0.20 to 0.

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.