Abstract: A heat exchanger includes a housing with an inlet port, an outlet port, an interior facing surface defining a coolant channel, a first opening surrounded by an exterior facing surface, and a second opening defined by a first inner diameter. A tube assembly defines a plurality of exhaust gas flow channels and a plurality of coolant cross channels within the housing. A first diffuser directs a first fluid into the tube assembly and is joined to a first header plate, which separates the first fluid from a second fluid within the coolant channel. A second diffuser directs the first fluid out of the tube assembly. The second diffuser is located within the second opening and sealed to the second opening by seals around the second diffuser.

Abstract: A charge air cooler includes a battery of round tubes that extend between a first header plate and a second header plate arranged at a first end and a second end, respectively, of the charge air cooler. Stresses in corner tubes caused by differential thermal expansion between the tubes and side plates of the charge air cooler are reduced by having a reduced thickness over a portion of the header plates, or by directing a portion of the coolant through the side plates, or both.

Abstract: The invention relates to an heat exchanger possibly for exchanging heat within a vehicle. The heat exchanger includes a housing with an inlet port, an outlet port, an interior facing surface defining a coolant channel, a first opening surrounded by an exterior facing surface, and a second opening defined by a first inner diameter. A tube assembly defines a plurality of exhaust gas flow channels and a plurality of coolant cross channels within the housing. A first diffuser directs a first fluid into the tube assembly. The first diffuser is joined to the exterior facing surface, and this joint is sealed. A cap surface of the first diffuser encloses the first opening and caps the coolant channel. The first diffuser is joined to a first header plate, which separates the first fluid from a second fluid within the coolant channel. A second diffuser defines a directs the first fluid out of the tube assembly.

Abstract: An exhaust gas cooler includes tubes to convey an exhaust gas through the cooler, a header plate to receive ends of the tubes, and a diffuser. The diffuser and the header plate together define an inlet plenum for the exhaust gas. The diffuser includes a connection flange to join the diffuser to the header plate, and the connection flange is substantially shielded from the flow of exhaust gas passing through the inlet plenum.

Abstract: An exhaust gas cooler includes tubes to convey an exhaust gas through the cooler, a header plate to receive ends of the tubes, and a diffuser. The diffuser and the header plate together define an inlet plenum for the exhaust gas. The diffuser includes a connection flange to join the diffuser to the header plate, and the connection flange is substantially shielded from the flow of exhaust gas passing through the inlet plenum.

Abstract: An exhaust gas recirculation cooler includes an inlet configured to receive exhaust gas from an engine, an outlet configured to direct the exhaust gas back toward the engine, and an exhaust gas flow conduit. The flow conduit includes a first end adjacent the inlet, a second end adjacent the outlet, a first narrow side, a second narrow side, substantially flat broad sides extending between the narrow sides, a first channel adjacent the first narrow side and extending between the ends, a second channel adjacent the second narrow side and extending between the ends, and a plurality of third channels located between the first and second channels and extending between the ends. A plate is located at one end of the flow conduit to inhibit the exhaust gas from flowing through at least one of the first channel and the second channel while allowing exhaust gas flow through the third channels.

Abstract: An exhaust gas recirculation cooler includes an inlet configured to receive exhaust gas from an engine, an outlet configured to direct the exhaust gas back toward the engine, and an exhaust gas flow conduit. The flow conduit includes a first end adjacent the inlet, a second end adjacent the outlet, a first narrow side, a second narrow side, substantially flat broad sides extending between the narrow sides, a first channel adjacent the first narrow side and extending between the ends, a second channel adjacent the second narrow side and extending between the ends, and a plurality of third channels located between the first and second channels and extending between the ends. A plate is located at one end of the flow conduit to inhibit the exhaust gas from flowing through at least one of the first channel and the second channel while allowing exhaust gas flow through the third channels.