Abstract: A heat exchanger (10) is provided and in a highly preferred form is an EGR cooler (52) having first and second passes (56A,56B) that are connected to an inlet/outlet manifold (70) by a pair of corresponding thermal expansion joints (87,93) to allow differential thermal expansion between the various structural components of the heat exchanger (10).

Abstract: A heat exchanger (10) is provided and in a highly preferred form is an EGR cooler (52) having first and second passes (56A,56B) that are connected to an inlet/outlet manifold (70) by a pair of corresponding thermal expansion joints (87,93) to allow differential thermal expansion between the various structural components of the heat exchanger (10).

Abstract: The present invention provides, among other things, a heat exchanger including a plurality of tubes providing a flow path for a first fluid, a fin supported between two of the plurality of tubes and positioned along a flow path for a second fluid. Together, the fin and the plurality of tubes at least partially define a heat exchanger core. The heat exchanger can also include first and second tanks positioned adjacent to opposite ends of the plurality of tubes and an elastically deformable side part extending across the heat exchanger core and including a pair of integrally formed caps for closing openings in the first and second tanks.

Abstract: The present invention provides a heat exchanger for transferring heat between a first working fluid and a second working fluid, including a pair of spaced apart headers, a number of tubes extending between the pair of headers and providing a flow path for the first working fluid and being positioned along a flow path for the second working fluid, and an insert supportable in one of the tubes and having a fold extending in a direction substantially parallel to the flow path for the first working fluid through the tubes. The fold can define first and second legs of the insert. A dimple can be formed on the first leg and a protrusion can be formed on the second leg opposite to the dimple on the first leg.

Abstract: A heat exchanger (10) is provided and in a highly preferred form is an EGR cooler (52) having first and second passes (56A,56B) that are connected to an inlet/outlet manifold (70) by a pair of corresponding thermal expansion joints (87,93) to allow differential thermal expansion between the various structural components of the heat exchanger (10).

Abstract: An improved combustion air charger, such as a turbocharger or a supercharger, includes a housing (10) having a rotary shaft (18) journalled therein. At least one compressor wheel (20,22) is located on the shaft (18). The housing (10) includes an ambient inlet (30) as well as a compressed air outlet (32) and a heat exchanger (36) is located between at least one of the compressor wheels (20) and the outlet (32) and is arranged so that air flow through the heat exchanger (36) is generally in the radially inward direction.

Abstract: A header construction intended for use in a heat exchanger (36) employed in a relatively high pressure application includes an array of generally parallel tube runs (84) with fins (82) extending between adjacent ones of the tube runs. At least one relatively flat header plate (86) has a plurality of tube slots (88) for receiving ends (90) of the tubes (84) and a tank (94) is mounted to and sealed to the header plate (86). Peripheral flanges (112) are located about tube slots (86) in the headers and a header reinforcing plate (114) is bonded to the header plate (86) oppositely of the tank (94). Stiffening beads in the form of flanges (120) are located on the header reinforcing plate (114) between openings (118) therein through which the tubes (84) pass and extend away from the header plate (86).

Abstract: A compact rotary compressor unit within internal intercooling includes a rotary shaft (10) with at least one compressor wheel (14,16) mounted thereon for rotation therewith. The compressor wheel (14,16) has an inlet end (18) of relatively small diameter and a radial discharge end (20) of relatively large diameter. A nominally donut-shaped intercooling heat exchanger (42) is centered about the shaft (10) to receive compressed air from the compressor wheel and cool the same. Both the compressor wheel (14,16) and the heat exchanger (42) are confined in a housing (28).

Abstract: A header construction intended for use in a heat exchanger (36) employed in a relatively high pressure application includes an array of generally parallel tube runs (84) with fins (82) extending between adjacent ones of the tube runs. At least one relatively flat header plate (86) has a plurality of tube slots (88) for receiving ends (90) of the tubes (84) and a tank (94) is mounted to and sealed to the header plate (86). Peripheral flanges (112) are located about tube slots (86) in the headers and a header reinforcing plate (114) is bonded to the header plate (86) oppositely of the tank (94). Stiffening beads in the form of flanges (120) are located on the header reinforcing plate (114) between openings (118) therein through which the tubes (84) pass and extend away from the header plate (86).

Abstract: An improved combustion air charger, such as a turbocharger or a supercharger, includes a housing (10) having a rotary shaft (18) journalled therein. At least one compressor wheel (20,22) is located on the shaft (18). The housing (10) includes an ambient inlet (30) as well as a compressed air outlet (32) and a heat exchanger (36) is located between at least one of the compressor wheels (20) and the outlet (32) and is arranged so that air flow through the heat exchanger (36) is generally in the radially inward direction.

Abstract: A turbulator (60A-60K) is provided for use in the heat exchange units (34) of heat exchangers. The turbulator (60A-60K) includes a sheet (62A, 62C) of material. The sheet (62A, 62C) includes a plurality of strand-like rows (64A, 64C) of alternating crests (66A, 66C) and valleys (68A, 68C). The crests (66A, 66C) and valleys (68A, 68C) in each row (64A, 64C) are offset with respect to the crests (66A, 66C) and valleys (68A, 68C) in any immediately adjacent row (64A, 64C). Each of the rows (64A, 64C) has an interface with any immediately adjacent row (64A, 64C). The interfaces are perforated so that valleys (68A, 68C) in each row (64A, 64C) are in fluid communication with immediately adjacent crests (66A, 66C) in any immediately adjacent row (64A, 64C) and crests (66A, 66C) in each row (64A, 64C) are in fluid communication with any immediately adjacent valleys (68A, 68C) in any immediately adjacent row (64A, 62C).

Abstract: A turbulator (60A-60K) is provided for use in the heat exchange units (34) of heat exchangers. The turbulator (60A-60K) includes a sheet (62A, 62C) of material. The sheet (62A, 62C) includes a plurality of strand-like rows (64A, 64C) of alternating crests (66A, 66C) and valleys (68A, 68C). The crests (66A, 66C) and valleys (68A, 68C) in each row (64A, 64C) are offset with respect to the crests (66A, 66C) and valleys (68A, 68C ) in any immediately adjacent row (64A, 64C). Each of the rows (64A, 64C) has an interface with any immediately adjacent row (64A, 64C). The interfaces are perforated so that valleys (68A, 68C) in each row (64A, 64C) are in fluid communication with immediately adjacent crests (66A, 66C) in any immediately adjacent row (64A, 64C) and crests (66A, 66C) in each row (64A, 64C) are in fluid communication with any immediately adjacent valleys (68A, 68C) in any immediately adjacent row (64A, 62C).

Abstract: A turbulator (60A-60K) is provided for use in the heat exchange units (34) of heat exchangers. The turbulator (60A-60K) includes a sheet (62A, 62C) of material. The sheet (62A, 62C) includes a plurality of strand-like rows (64A, 64C) of alternating crests (66A, 66C) and valleys (68A, 68C). The crests (66A, 66C) and valleys (68A, 68C) in each row (64A, 64C) are offset with respect to the crests (66A, 66C) and valleys (68A, 68C) in any immediately adjacent row (64A, 64C). Each of the rows (64A, 64C) has an interface with any immediately adjacent row (64A, 64C). The interfaces are perforated so that valleys (68A, 68C) in each row (64A, 64C) are in fluid communication with immediately adjacent crests (66A, 66C) in any immediately adjacent row (64A, 64C) and crests (66A, 66C) in each row (64A, 64C) are in fluid communication with any immediately adjacent valleys (68A, 68C) in any immediately adjacent row (64A, 64C).