Abstract: Apparatus and method for cooling heated fluids, such as exhaust gases, flowing through a heat exchanger comprising one or more exhaust plenums and one or more coolant plenums, and providing increased coolant velocity in that portion of the coolant plenums contacting the inlet portion of the exhaust plenums. Local increased coolant velocity is provided by any means, including decreasing the area-in-flow of the coolant plenums wherein increased velocity is desired, shaping or baffling either or both inlet or outlet coolant tanks in fluidic contact with coolant plenums wherein increased velocity is desired, or a combination thereof.

Abstract: An exemplary heat exchanger includes a heat exchanger core having a core side fluid space and a cover plate and a substantially U-shaped wall fitted at one end with an inlet header and, at an opposing end, with an outlet header, which in combination with the cover plate, define a shell side fluid space. In this example, the cover plate forms two seals with two opposing sides of the U-shaped wall, forms a seal with the inlet header and forms a seal with the outlet header. Such a heat exchange may be suitable for use as an EGR cooler. Other exemplary devices, methods and systems are disclosed.

Abstract: Heat exchangers of this invention include a shell having an inner chamber defined by an inside wall surface, and having at least one opening adjacent an end of the shell. A tube bundle comprising a plurality of assembled together tubes are disposed within the inner chamber. A header plate is attached to the tubes and is positioned adjacent an end of the tube bundle. The header plate includes an outside diameter that fits within the shell inside wall surface to provide a nested attachment junction therebetween. The header plate and shell are fixedly connected to one another by use of a braze joint formed by the placement of brazing material between the interfacing header plate and the shell surface sections. A tank is attached to the shell adjacent the shell end.

Abstract: Apparatus and method for cooling heated fluids, such as exhaust gases, flowing through a heat exchanger comprising one or more exhaust plenums and one or more coolant plenums, and providing increased coolant velocity in that portion of the coolant plenums contacting the inlet portion of the exhaust plenums. Local increased coolant velocity is provided by any means, including decreasing the area-in-flow of the coolant plenums wherein increased velocity is desired, shaping or baffling either or both inlet or outlet coolant tanks in fluidic contact with coolant plenums wherein increased velocity is desired, or a combination thereof.

Abstract: An exemplary heat exchanger, suitable for use in exhaust gas recirculation to cool exhaust gas, includes a cover plate having a plurality of openings, an upper plate having a plurality of openings, a lower plate having a plurality of openings and a bottom plate where seals exist between various plates to form at least one gas flow space and at least one liquid flow space. Various other exemplary heat exchanger configurations are also disclosed.

Abstract: Heat exchangers, constructed in accordance with principles of this invention, comprise a plurality of first passages, for transporting a first fluid or gas therethrough, and one or more second passages for transporting a second fluid or gas therethrough. The second passages are positioned adjacent to the first passages to permit a desired transfer of thermal energy from the first passages to the second passages. At least one manifold is placed in communication with one of the first or second passages. The manifold includes an opening disposed therethrough for receiving or dispensing the first or second fluid or gas to or from the first or second passages. The heat exchanger includes a flow director disposed therein for diverting or distributing the flow of first or second fluid or gas in a manner different from a natural fluid or gas flow within the heat exchanger.

Abstract: An apparatus and method for cooling hot fluids, especially exhaust gases, with a multi-pass cooler core. The cooler core is particularly useful for cooling exhaust gases flowing in an exhaust gas recirculation (EGR) system or regime in operative association with an internal combustion engine, such as a diesel engine. Cooled gases are recirculated to the engine input to help reduce noxious exhaust emissions. The invention utilizes unequal areas-in-flow between the first exhaust pass through the core and the second and subsequent passes through the core. The first pass through the core features an area-in-flow comparatively larger than the area-in-flow of the second pass. The difference in areas-in-flow between passes influences gas velocities to reduce fouling, despite changes in exhaust gas temperature between passes through the core.

Abstract: A heat exchanger tube is provided that includes an inner diameter, an outer diameter and a longitudinal axis. The heat exchanger includes at least two spiral upsets protruding from the inner diameter of the tube and spiraling around the longitudinal axis of a length of the tube. The at least two spiral upsets include a first spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis, and a second spiral upset having a cross-sectional shape, a depth of protrusion from the inner diameter, a pitch, and an angle with respect to the longitudinal axis. In one embodiment, the angle of the first spiral upset with respect to the longitudinal axis is approximately equal to the angle of the second spiral upset with respect to the longitudinal axis, such that the first and second spiral upsets are approximately parallel.

Abstract: There is provided a heat exchanger, such as an exhaust gas cooler, that has a removable core at least partially disposed in a shell. Tubes extending through the shell fluidly connect tanks at both ends of the shell so that thermal energy can be transferred between a first fluid in the shell and a second fluid in the tubes. At least one of the tanks is defined partially by a tube sheet, and the tank is structured to be moved axially through the shell in a direction toward the opposite tank and removed from the shell with the tubes. A sealing member is disposed between the movable tank and the shell to prevent fluid from flowing therebetween.

Abstract: Heat exchanger header tanks are constructed from a basic set of components. The basic components are castings and simple formed sheet parts. The components are assembled to produce a heat exchanger tank having a desired size and geometry.

Abstract: An apparatus and method for cooling hot fluids, especially exhaust gases, with a multi-pass cooler core. The cooler core is particularly useful for cooling exhaust gases flowing in an exhaust gas recirculation (EGR) system or regime in operative association with an internal combustion engine, such as a diesel engine. Cooled gases are recirculated to the engine input to help reduce noxious exhaust emissions. The invention utilizes unequal areas-in-flow between the first exhaust pass through the core and the second and subsequent passes through the core. The first pass through the core features an area-in-flow comparatively larger than the area-in-flow of the second pass. The difference in areas-in-flow between passes influences gas velocities to reduce fouling, despite changes in exhaust gas temperature between passes through the core.

Abstract: An apparatus and method for cooling hot fluids, especially exhaust gases, with a multi-pass cooler core. The cooler core is particularly useful for cooling exhaust gases flowing in an exhaust gas recirculation (EGR) system or regime in operative association with an internal combustion engine, such as a diesel engine. Cooled gases are recirculated to the engine input to help reduce noxious exhaust emissions. The invention utilizes unequal areas-in-flow between the first exhaust pass through the core and the second and subsequent passes through the core. The first pass through the core features an area-in-flow comparatively larger than the area-in-flow of the second pass. The difference in areas-in-flow between passes influences gas velocities to reduce fouling, despite changes in exhaust gas temperature between passes through the core.

Abstract: Heat exchanger header tanks are constructed from a basic set of components. The basic components are castings and simple formed sheet parts. The components are assembled to produce a heat exchanger tank having a desired size and geometry.

Abstract: A side sheet of a radiator has a thermal expansion joint to allow thermal relief in the radiator as the radiator expands due to temperature variations during operation. The thermal expansion joint is formed by first brazing the side sheet to the radiator core and then cutting through the side sheet.