Abstract: A tube-to-header sealing system for a heat exchanger comprises a pair of mating header plates, each header plate having a wall with a plurality of openings therein and including a continuous depression along the circumference of each header plate opening which forms one-half of an O-ring groove. Each of a plurality of O-rings is positioned in each O-ring groove and the header plates are secured together such that the header plate plurality of openings are aligned and trap each of the plurality of O-rings in O-ring grooves. A plurality of spaced-apart tubes each having a tube end secured in an opening in the wall of the header to form a tube-to-header joint are expanded outwardly to provide sufficient O-ring deformation to obtain a seal. In service, the resiliency of the O-ring seal allows for expansion and contraction of the tubes without the build-up of high stresses at the tube-to-header joint.

Abstract: A modular heat exchanger assembly for ultra-large radiator applications. At least two heat exchanger cores are arranged in parallel flow, each core including inlet and outlet tanks sealingly attached to opposing headers at each end of a plurality of tubes. Each header is formed by securing mating header plates having mating openings. A plurality of O-rings are trapped within O-ring grooves formed by continuous depressions around each of the mating openings, and a portion of each tube is disposed within one of the O-rings and expanded outwardly to form a seal at each tube-to-header joint. A common tank is connected between tanks at adjacent ends of each heat exchanger core, and separate tanks are connected to the tank at the opposing ends of each core. The separate tanks may be inlet tanks and the common tank may be an outlet tank for fluid, or the flow path may be reversed.

Abstract: A header for a heat exchanger manifold comprises a header plate with a periphery, a plurality of tube openings within the header plate periphery adapted to connect to tubes of a heat exchanger core, a groove around the periphery of the header plate to receive a foot of a tank, the groove comprising inner and outer vertical walls and a lower wall disposed therebetween, and a header groove reinforcement member secured to and extending along an outer surface of the header groove and along at least a portion of the length of the header plate in a direction transverse to the header groove. The header groove reinforcement member comprises a first portion extending along at least a portion of a length of the outer vertical wall in the direction of a distal end, and a second portion extending past a proximal end of the inner vertical wall and along at least a portion of the length of the header plate.

Abstract: A header for a heat exchanger manifold comprises a header plate with a periphery, a plurality of tube openings within the header plate periphery adapted to connect to tubes of a heat exchanger core, a groove around the periphery of the header plate to receive a foot of a tank, the groove comprising inner and outer vertical walls and a lower wall disposed therebetween, and a header groove reinforcement member secured to and extending along an outer surface of the header groove and along at least a portion of the length of the header plate in a direction transverse to the header groove. The header groove reinforcement member comprises a first portion extending along at least a portion of a length of the outer vertical wall in the direction of a distal end, and a second portion extending past a proximal end of the inner vertical wall and along at least a portion of the length of the header plate.

Abstract: A heat exchanger tube has a tube end having two extended portions substantially opposite the other around the periphery of the tube end, and two shortened portions, each positioned between the two extended portions and substantially opposite the other around the periphery of the tube end. The tube end may be formed by removing opposite portions of the tube by cutting a disc-shaped portion with a generally smoothly curving periphery along a major portion of the width of the tube. Each tube is oriented within an opening in the header wall of a heat exchanger assembly having a header portion integral with a tank portion, such that the tube end two extended portions are oriented substantially perpendicular to the direction of fluid flow within the header and the tube end two shorter portions are oriented substantially in the direction of fluid flow in order to reduce interference with fluid flow.

Abstract: A tube-to-header sealing system for a heat exchanger comprises a pair of mating header plates, each header plate having a wall with a plurality of openings therein and including a continuous depression along the circumference of each header plate opening which forms one-half of an O-ring groove. Each of a plurality of O-rings is positioned in each O-ring groove and the header plates are secured together such that the header plate plurality of openings are aligned and trap each of the plurality of O-rings in O-ring grooves. A plurality of spaced-apart tubes each having a tube end secured in an opening in the wall of the header to form a tube-to-header joint are expanded outwardly to provide sufficient O-ring deformation to obtain a seal. In service, the resiliency of the O-ring seal allows for expansion and contraction of the tubes without the build-up of high stresses at the tube-to-header joint.

Abstract: A modular heat exchanger assembly comprises at least two heat exchanger cores arranged in parallel flow, each heat exchanger core including a plurality of tubes, fins between the tubes and opposing headers sealingly attached at each end of the tubes. A common tank is positioned between the heat exchanger cores and is connected to a header at one end of each heat exchanger core, and separate tanks are connected to a header at the other end of each of the heat exchanger cores. The separate tanks may be inlet tanks for fluid passing into the heat exchanger assembly and the common tank may be an outlet tank, or the flow path may be reversed. A core support member may be disposed between each pair of heat exchanger cores to force entering air to either side of the core support member and direct air flow to the fins and tubes of the heat exchanger cores.

Abstract: A heat exchanger assembly comprises at least two heat exchanger cores arranged in parallel flow, each heat exchanger core including a plurality of tubes, fins between the tubes and opposing headers sealingly attached at each end of the tubes. A common tank is positioned between the at least two heat exchanger cores and connected to a header at one end of each heat exchanger core, and separate tanks are connected to a header at the other end of each of the at least two heat exchanger cores. The separate tanks may be inlet tanks for fluid passing into the heat exchanger assembly and the common tank may be an outlet tank for fluid passing out of the heat exchanger assembly, or the flow path may be reversed, with the common tank being an inlet tank and the separate tanks being outlet tanks.

Abstract: A tube-to-header sealing system for a heat exchanger comprises a pair of mating header plates, each header plate having a wall with a plurality of openings therein and including a continuous depression along the circumference of each header plate opening which forms one-half of an O-ring groove. Each of a plurality of O-rings is positioned in each O-ring groove and the header plates are secured together such that the header plate plurality of openings are aligned and trap each of the plurality of O-rings in O-ring grooves. A plurality of spaced-apart tubes each having a tube end secured in an opening in the wall of the header to form a tube-to-header joint are expanded outwardly to provide sufficient O-ring deformation to obtain a seal. In service, the resiliency of the O-ring seal allows for expansion and contraction of the tubes without the build-up of high stresses at the tube-to-header joint.

Abstract: A heat exchanger tube has a tube end having two extended portions substantially opposite the other around the periphery of the tube end, and two shortened portions, each positioned between the two extended portions and substantially opposite the other around the periphery of the tube end. The tube end may be formed by removing opposite portions of the tube by cutting a disc-shaped portion with a generally smoothly curving periphery along a major portion of the width of the tube. Each tube is oriented within an opening in the header wall of a heat exchanger assembly having a header portion integral with a tank portion, such that the tube end two extended portions are oriented substantially perpendicular to the direction of fluid flow within the header and the tube end two shorter portions are oriented substantially in the direction of fluid flow in order to reduce interference with fluid flow.

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 bank.

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 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 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 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: 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 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 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.