Abstract: The use of relatively heavy, large profile headers in a heat exchanger are avoided through a header construction wherein headers (20, 22) are formed of header plates (34) tapped with tank plates (36) having a concave surface (38) facing the header plate (34). The header plates (34) include a plurality of flanges (82) directed away from the tank plates (36) surrounding elongated slots (48). Each of the flanges (82) includes a pilot surface (80) extending about the associated slot (48) for receiving the end (90) of a flattened tube (20). The construction prevents the ends (90) of the tubes (28) from entering the header chambers (42) to a location whereat they could disrupt the flow of a heat exchange fluid therein to prevent uniform distribution of the same throughout the associated header (20, 22).

Abstract: Thermal and pressure related fatigue or stress in the header plates (26, 28) of a charge air cooler is avoided in a structure wherein the header plates (26, 28) are formed of a channel having a central web (80) flanked by legs (82, 84) and provided with apertures (86) for receiving the ends of tubes (36). The apertures (86), on the side thereof between the legs (82, 84), are provided with peripheral flanges (88, 90, 92, 94) and on the opposite side are substantially surrounded by concave camming surfaces (96, 98).