Abstract: A heat exchanger includes a shell housing a plurality of tubes and defining an exhaust fluid flow path within a first volume enclosed by the shell. The outer surfaces of the plurality of tubes are in fluid communication with the exhaust fluid flow path. The heat exchanger includes a cap attached to a first end of the shell and defining a second volume. A header is configured to separate the first volume from the second volume, flex with thermal expansion, and define tube inlet and outlet positions. The tube inlets and outlets are in fluid communication with a source fluid flow path, and each tube is substantially U-shaped and defines a flow path of the source fluid within the exhaust fluid flow path. The heat exchanger includes at least one longitudinal flow baffle within the shell configured to reduce an amount of exhaust fluid that may bypass the tubes.

Abstract: A heat exchanger includes a shell housing a plurality of tubes and defining an exhaust fluid flow path within a first volume enclosed by the shell. The outer surfaces of the plurality of tubes are in fluid communication with the exhaust fluid flow path. The heat exchanger includes a cap attached to a first end of the shell and defining a second volume. A header is configured to separate the first volume from the second volume, flex with thermal expansion, and define tube inlet and outlet positions. The tube inlets and outlets are in fluid communication with a source fluid flow path, and each tube is substantially U-shaped and defines a flow path of the source fluid within the exhaust fluid flow path. The heat exchanger includes at least one longitudinal flow baffle within the shell configured to reduce an amount of exhaust fluid that may bypass the tubes.

Abstract: The plate-fin heat exchanger includes a first fluid pathway running along a first axis, a second fluid pathway running along a second axis perpendicular to the first axis, and a blocker bar having an inlet face and an outlet face. The blocker bar inlet face coincides with a heat exchanger face. The blocker bar is at an inlet of the second fluid pathway and receives a second fluid. The outlet face of the blocker bar is at the inlet of the second fluid pathway. The blocker bar includes a set of spaced apart pores that extend from the inlet face to the outlet face.

Abstract: A plate-fin heat exchanger adapted to reduce thermal fatigue is described. The plate-fin heat exchanger includes a cold fluid pathway running along a first axis, a hot fluid pathway running along a second axis perpendicular to the first axis, and at least one porous blocker bar running along the first axis. The porous blocker bar includes a set of pores adapted to control the flow along the hot fluid pathway and coupled to an inlet of the hot fluid pathway.