Abstract: The present invention provides a heat exchanger for transferring heat between a first working fluid and a second working fluid. The heat exchanger can include a corrugated fin positionable along a flow path of the first working fluid between adjacent tube walls and being operable to increase heat transfer between the first working fluid and the second working fluid. The fin can include a leg defined between adjacent folds. The heat exchanger can also include a plurality of convolutions extending inwardly from a distal end of the leg and terminating at different distances from the end.

Abstract: A charge air cooler includes a housing and a heat exchanger core positioned within the housing. The heat exchanger core includes a first core section, a second core section, and a centrally located section positioned between the first core section and the second core section. The charge air cooler also includes a plurality of coolant circuits. Each coolant circuit extends through at least one of the first and second core sections. The charge air cooler further includes a coolant inlet extending from the centrally located section to deliver coolant to the plurality of coolant circuits, and a coolant outlet extending from the centrally located section to receive coolant from the plurality of coolant circuits. The charge air cooler also includes a fastener extending through the centrally located section of the core to secure the core to the housing.

Abstract: A charge air cooler includes a housing and a heat exchanger core positioned within the housing. The heat exchanger core includes a first core section, a second core section, and a centrally located section positioned between the first core section and the second core section. The charge air cooler also includes a plurality of coolant circuits. Each coolant circuit extends through at least one of the first and second core sections. The charge air cooler further includes a coolant inlet extending from the centrally located section to deliver coolant to the plurality of coolant circuits, and a coolant outlet extending from the centrally located section to receive coolant from the plurality of coolant circuits. The charge air cooler also includes a fastener extending through the centrally located section of the core to secure the core to the housing.

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 an exhaust gas recirculation cooler for transferring heat from engine exhaust to coolant including a pair of spaced apart headers, a tube body extending between the pair of headers and positioned along a flow path for the coolant and at least partially defining a flow path for the engine exhaust along a length of the tube between the pair of headers, and a corrugated insert supported in an interior of the tube and having a height in a direction of a plurality of corrugations and a width between about 8.6 and about 13.5 times the height. The width can be substantially perpendicular to the length of the tube and can be substantially perpendicular to the height of the insert.

Abstract: The present invention provides a heat exchanger for transferring heat between a first working fluid and a second working fluid. The heat exchanger can include a corrugated fin positionable along a flow path of the first working fluid between adjacent tube walls and being operable to increase heat transfer between the first working fluid and the second working fluid. The fin can include a leg defined between adjacent folds. The heat exchanger can also include a plurality of convolutions extending inwardly from a distal end of the leg and terminating at different distances from the end.

Abstract: The present invention provides an exhaust gas recirculation cooler for transferring heat from engine exhaust to coolant including a pair of spaced apart headers, a tube body extending between the pair of headers and positioned along a flow path for the coolant and at least partially defining a flow path for the engine exhaust along a length of the tube between the pair of headers, and a corrugated insert supported in an interior of the tube and having a height in a direction of a plurality of corrugations and a width between about 8.6 and about 13.5 times the height. The width can be substantially perpendicular to the length of the tube and can be substantially perpendicular to the height of the insert.

Abstract: A heat exchanger including a first flow path for a first working fluid, a second flow path for a second working fluid, a tube at least partially defining one of the first and second flow paths, and a corrugated insert secured to the tube and positioned along the first flow path. A structural deficit is provided at a location on the insert such that structural failures occur at the location in preference to other locations on the insert.

Abstract: A heat exchanger that includes a heat exchanger core including a plurality of stacked tubes defining a fluid flow path, a housing substantially surrounding the heat exchanger core, and an elastomeric member positioned between the heat exchanger housing and the heat exchanger core and deformable to allow movement of one of the heat exchanger core and the housing relative to an other of the heat exchanger core and the housing in at least two substantially perpendicular directions.

Abstract: The present invention provides a heat exchanger for transferring heat between a first working fluid and a second working fluid. The heat exchanger can include a corrugated fin positionable along a flow path of the first working fluid between adjacent tube walls and being operable to increase heat transfer between the first working fluid and the second working fluid. The fin can include a leg defined between adjacent folds. The heat exchanger can also include a plurality of convolutions extending inwardly from a distal end of the leg and terminating at different distances from the end.

Abstract: An integrated exhaust gas recirculation (EGR) cooler with dual coolant loops comprises an exhaust gas inlet and an exhaust gas outlet for recirculating exhaust gas. An exhaust gas flow path extends between the exhaust gas inlet and the exhaust gas outlet to direct recirculating exhaust gas from the exhaust gas inlet to the exhaust gas outlet. A first coolant flow path extends between a first coolant inlet and a first coolant outlet to direct a first coolant flow from the EGR cooler in heat exchange relation with the exhaust gas flow path. A second coolant flow path extends between a second coolant inlet and a second coolant outlet to direct a second coolant flow through the EGR cooler in heat exchange relation with the exhaust gas flow path.

Abstract: The invention provides, among other things, a heat exchanger including a header, a number of tubes extending outwardly from the header, and an elastic sleeve supported between the header and one of the tubes to allow movement of the tube relative to the header in a direction substantially parallel to a length of the tube defined between a first end of the tube adjacent to the header and a second end of the tube spaced away from the header. Together, the tube, the header, and the elastic sleeve can at least partially define a flow path for a working fluid.

Abstract: An integrated exhaust gas recirculation (EGR) cooler with dual coolant loops comprises an exhaust gas inlet and an exhaust gas outlet for recirculating exhaust gas. An exhaust gas flow path extends between the exhaust gas inlet and the exhaust gas outlet to direct recirculating exhaust gas from the exhaust gas inlet to the exhaust gas outlet. A first coolant flow path extends between a first coolant inlet and a first coolant outlet to direct a first coolant flow from the EGR cooler in heat exchange relation with the exhaust gas flow path. A second coolant flow path extends between a second coolant inlet and a second coolant outlet to direct a second coolant flow through the EGR cooler in heat exchange relation with the exhaust gas flow path.

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 heat-exchanger assembly, which can be advantageously employed as an intercooler for an air-charging system for an internal combustion engines includes a plurality of generally wedge-shaped coolant tubes through which coolant is directed for effecting cooling of compressed air flowing about the tubes. In order to promote efficient operation, each of the wedge-shaped cooling tubes includes a plurality of coolant passages of substantially identical hydraulic diameter or cross-sectional area, thereby promoting uniform flow of coolant through each coolant tube. Each coolant tube includes outer walls which may be of a substantially uniform thickness, or which may increase in thickness across the width of the tube.

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 rotary compressor machine, such as a combustion air charger, includes a rotatable shaft (18) having at least one compressor wheel (20,22) thereon and disposed within a housing (12,14). A donut-shaped heat exchanger (36) is located within the housing (12,14) between the compressor wheel (22) and an outlet (32) from the housing and has radially inner and outer peripheries (40,42). The outer periphery (40) defines an inlet for the heat exchanger (36) for gas discharged by the compressor wheel (20). The heat exchanger is provided with radially inner and outer flow paths defined by tubes (92) and includes a combined manifold and tank (44) which is secured and sealed to a header plate (88) receiving the tubes (92). The combined manifold and tank (44) includes first, second and third axially spaced walls (96,98,100) with each having a central opening (110,112,114).

Abstract: Improved efficiency is obtained in a rotary machine having a rotary shaft (18) mounting a compressor wheel (20) that discharges into a heat exchanger (36) having a core (82) with a central opening (42) in surrounding relation to the shaft (18). The heat exchanger (36) includes a coolant tank (90) on one side of the core (82) and in fluid communication with the same which serves as one boundary of radially extending space (68) through which a gas is discharged by a compressor wheel (20). A deswirling vane structure (80) causes gas discharged by the compressor wheel (22) to move radially outward within the space (68) and is formed of a material of good thermal conductivity and thermally bridged to the tank (90) to conduct heat thereto to be rejected to coolant in the tank.