Abstract: An oil cooler for use in a motor vehicle radiator tank is made of a plurality of plate assemblies, each comprising a pair of plate shells. Each plate shell has opposite upstanding walls, and the plate shells are nested so that the upstanding walls are in contact and sealed along their peripheries. The plate shells have deformed walls forming serpentine passageways in thermally conductive communication with the plate shells to transfer heat from the oil, and deformed projections extending into the interior space in passageways cause turbulence in the oil. Fittings for passage of oil into and out of the oil cooler have a flange with a groove and an elastomeric gasket with an elliptical cross section to seal the fittings to the tank wall opening. The oil cooler is mounted within the tank so that it is located approximately equidistant from the front and rear tank walls.

Abstract: A system for aligning and connecting a threaded male fastener for securing an oil line to a correspondingly threaded female fastener at the inlet of an oil cooler in a radiator tank has a guide sleeve having a cylindrical internal surface and a central axis adapted to be aligned with a central axis of the female fastener, and a guide member having a cylindrical external surface and a central axis adapted to be aligned with a central axis of the other of the male fastener. The guide member cylindrical external surface is slidingly and rotatably movable with respect to the guide sleeve cylindrical internal surface. The guide member is adapted to be slid into the guide sleeve, such that the threaded male and female fasteners may be coaxially aligned and contacted, and the guide member may be rotated with respect to the guide sleeve so that threads of the male fastener engage threads of the female fastener.

Abstract: A system for cooling charge air from a turbo- or supercharger and exhaust gas recirculated from an exhaust gas recirculation valve in an internal combustion engine. The system includes a radiator and parallel charge air and exhaust gas heat exchanger units, the charge air heat exchanger unit having aluminum tubes and fins for air cooling the charge air, and the exhaust gas heat exchanger unit having stainless steel tubes and fins. The charge air heat exchanger and the exhaust gas heat exchanger units are each disposed adjacent the radiator, on the same or opposite sides. Alternatively, there is provided a pair of combined charge air cooler and exhaust gas cooler heat exchanger units, with a first heat exchanger unit having stainless steel tubes and fins, and a second heat exchanger unit having aluminum tubes and fins. The heat exchanger units are disposed on opposites sides of the radiator.

Abstract: A radiator and oil cooler combination for an internal combustion engine includes a concentric type oil cooler in the radiator inlet or outlet tank. A baffle directs coolant flow around the oil cooler. In one embodiment, the baffle is between an inner surface of the outlet radiator tank housing and the outer wall of the oil cooler forming a barrier substantially filling the space therebetween. The baffle is located away from the ends of the oil cooler, intermediate the length thereof, and intermediate the length of the outlet radiator tank containing the tube openings. In another embodiment, the baffle is between and spaced from the oil cooler and the radiator core tube openings. The baffle extends along at least a portion of the length of the outlet radiator tank containing the tube openings and overlaps at least a portion of the length of the oil cooler. In a further embodiment, the baffle is located in the radiator tank near one end of the oil cooler and has an opening spaced from the oil cooler outer wall.

Abstract: A serpentine fin for assembly between tubes in a heat exchanger core, and a method of making same from a metal strip. The strip edges have a hem comprising a double thickness of the strip material extending inward from the edge. The metal strip has folds extending across the strip width such that the strip forms a serpentine shape, with the folds being adapted to contact the tubes in the heat exchanger core. Multiple rows of split louvers are disposed between adjacent folds. Each row of split louvers comprises louvers having openings extending in the direction of the strip length and formed in a pair of adjacent, spaced louver banks. Ribs are disposed parallel to the louver openings adjacent the strip edges and in at least one center portion of the strip between the strip edges, and extend across the pair of louver banks.

Abstract: A heat exchanger manifold with improved sealing between the tank and header. The manifold includes a plastic heat exchanger tank having an opening for mating with a header and a lip extending substantially around a periphery of the opening. The lip has an outer surface and an upper surface extending outward of the tank opening, and a ridge extending upward from a portion of the upper surface extending substantially around the tank. The manifold further includes an aluminum heat exchanger header adapted to connect to a heat exchanger core. The header has a groove around the periphery thereof receiving the tank lip and a plurality of plastically deformable tabs extending from an edge of the groove. The tabs are bent inward and contact the ridge on the tank lip to secure the tank to the header.

Abstract: A system for cooling charge air from a turbo- or supercharger and exhaust gas recirculated from an exhaust gas recirculation valve in an internal combustion engine. The system includes a radiator and parallel charge air and exhaust gas heat exchanger units, the charge air heat exchanger unit having aluminum tubes and fins for air cooling the charge air, and the exhaust gas heat exchanger unit having stainless steel tubes and fins. The charge air heat exchanger and the exhaust gas heat exchanger units are each disposed adjacent the radiator, on the same or opposite sides. Alternatively, there is provided a pair of combined charge air cooler and exhaust gas cooler heat exchanger units, with a first heat exchanger unit having stainless steel tubes and fins, and a second heat exchanger unit having aluminum tubes and fins. The heat exchanger units are disposed on opposites sides of the radiator.

Abstract: A method of manufacturing serpentine fins for assembly between tubes in a heat exchanger core. The method includes providing a flat metal strip and forming in the strip, multiple rows of split louvers. Each row of split louvers has louvers formed in pairs of adjacent, spaced louver banks extending across the width of the strip. Each row includes ribs formed in the strip parallel to the louver openings and extending across the pair of louver banks. The metal strip has unformed portions extending across the strip width between rows of split louvers for forming folds across the width of the strip. After forming the rows of split louvers, pressure is applied to the strip to cause the flat strip to buckle along the unformed portions forming folds in the strip resulting in the serpentine fin. Preferably, the strip has ribs formed both in the center portion and along the edges.

Abstract: A combined radiator and charge air cooler package includes a radiator having upper and lower portions for cooling engine coolant and a charge air cooler having upper and lower portions for cooling charge air. The upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper radiator portion, and the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower radiator portion. The upper radiator portion and the lower charge air cooler portion are aligned in a first plane, and the lower radiator portion and the upper charge air cooler portion are aligned in a second plane, behind the first plane. Ambient cooling air may flow in series through the upper radiator portion and the upper charge air cooler portion, and also through the lower charge air cooler portion and the lower radiator portion.

Abstract: A combined radiator and charge air cooler package comprises a radiator for cooling engine coolant, and a charge air cooler for cooling charge air having upper and lower portions. The upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper end of the radiator, and the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower end of the radiator, on the face side thereof. Ambient air may flow in series through the upper end of the radiator and the upper charge air cooler portion, and through the lower charge air cooler portion and the lower end of the radiator. The charge air cooler portions are operatively connected such that the charge air may flow between the lower manifold of the upper charge air cooler portion and the upper manifold of the lower charge air cooler portion.

Abstract: A combined radiator and charge air cooler package includes a radiator having upper and lower portions for cooling engine coolant and a charge air cooler having upper and lower portions for cooling charge air. The upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper radiator portion, and the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower radiator portion. The upper charge air cooler portion and the lower radiator portion are aligned in a first plane, and the lower charge air cooler portion and the upper radiator portion are aligned in a second plane, behind the first plane. Ambient cooling air may flow in series through the upper charge air cooler portion and the upper radiator portion, and also through the lower charge air cooler portion and the lower radiator portion.

Abstract: A combined radiator and charge air cooler package comprises a radiator for cooling engine coolant, and a charge air cooler for cooling charge air having upper and lower portions. The upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper end of the radiator, and the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower end of the radiator, on the face side thereof. Ambient air may flow in series through the upper end of the radiator and the upper charge air cooler portion, and through the lower charge air cooler portion and the lower end of the radiator. The charge air cooler portions are operatively connected such that the charge air may flow between the lower manifold of the upper charge air cooler portion and the upper manifold of the lower charge air cooler portion.

Abstract: A combined radiator and charge air cooler package comprises a radiator for cooling engine coolant, and a charge air cooler for cooling charge air having upper and lower portions. The upper charge air cooler portion is disposed in overlapping relationship and adjacent to the upper end of the radiator, and the lower charge air cooler portion is disposed in overlapping relationship and adjacent to the lower end of the radiator, on the face side thereof. Ambient air may flow in series through the upper end of the radiator and the upper charge air cooler portion, and through the lower charge air cooler portion and the lower end of the radiator. The charge air cooler portions are operatively connected such that the charge air may flow between the lower manifold of the upper charge air cooler portion and the upper manifold of the lower charge air cooler portion.