A tube stay mounting assembly includes a press assembly having a housing and a top block configured to flatten fins on a first surface of a finned tube. A press arm is operable to move the top block vertically with respect to the housing. A bottom block is configured to flatten fins on a second surface of the finned tube when the press arm is rotated and moves the top block downwardly. A tube stay clamping assembly includes a clamping housing configured to receive a tube stay having a top, bottom, rear, and front walls, the tube stay being configured to receive a flattened portion of the finned tube. A clamping arm is connected by linking arms to a clamping block, the clamping block configured to engage and force the front wall into snap-fit engagement with the top wall of the tube stay.

A diffuser plate for a thermal transfer device can include a body having a number of first apertures and a second aperture that traverse therethrough, where the first apertures are asymmetrically arranged with respect to the second aperture. The first apertures can have a first shape and a first size, and where the first apertures are configured to receive a plurality of tubes. The second aperture has a second size, where the second size is larger than the first size.

A tube stay mounting assembly includes a press assembly having a housing and a top block configured to flatten fins on a first surface of a finned tube. A press arm is operable to move the top block vertically with respect to the housing. A bottom block is configured to flatten fins on a second surface of the finned tube when the press arm is rotated and moves the top block downwardly. A tube stay clamping assembly includes a clamping housing configured to receive a tube stay having a top, bottom, rear, and front walls, the tube stay being configured to receive a flattened portion of the finned tube. A clamping arm is connected by linking arms to a clamping block, the clamping block configured to engage and force the front wall into snap-fit engagement with the top wall of the tube stay.

A counterflow heat exchanger includes a first fluid inlet, a first fluid outlet fluidly coupled to the first fluid inlet via a core section, a second fluid inlet, and a second fluid outlet fluidly coupled to the second fluid inlet via the core section. The core section includes a plurality of first fluid passages configured to convey the first fluid flow from the first fluid inlet toward the first fluid outlet, and a plurality of second fluid passages configured to convey the second fluid flow from the second fluid inlet toward the second fluid outlet such that the first fluid flow exchanges thermal energy with the second fluid flow at the core section. One or more drains are operably connected to the plurality of first fluid passages configured to remove condensation from an interior of the first fluid passages prior to the condensation reaching the first fluid outlet.

A baffle for a fluid collection portion of a thermal transfer device can include a body having an inner perimeter, an outer perimeter, and an asymmetric feature, where the asymmetric feature is configured to create a pressure drop within the fluid collection portion of the thermal transfer device. The inner perimeter can be configured to be at least as large as an inner surface of a first wall that forms the fluid collection portion of the thermal transfer device. The outer perimeter can be configured to be no larger than an outer surface of a second wall that forms the fluid collection portion of the thermal transfer device.

A heat exchanger has: a first manifold assembly having a stack of plates; a second manifold assembly having a stack of plates; and a plurality of tubes extending from the first manifold assembly to the second manifold assembly. The plurality of tubes is a plurality groups of tubes. For each of the groups of the tubes: the tubes of the group have first ends mounted between plates of the first manifold assembly; and the tubes of the group have second ends mounted between plates of the second manifold assembly.

Methods and systems are provided for directing the flow of recirculated exhaust gas (EGR) delivered to an EGR cooler. In one example, a method includes flowing EGR through an EGR cooler positioned in an EGR passage, the EGR cooler comprising a bypass passage, a first cooler core flow path, and a second cooler core flow path, and adjusting a valve of the EGR cooler to selectively block flow of the EGR through the bypass passage, the first cooler core flow path, and the second cooler core flow path. In this way, fouling of the EGR cooler may be reduced.

A tube stay mounting assembly includes a press assembly having a housing and a top block configured to flatten fins on a first surface of a finned tube. A press arm is operable to move the top block vertically with respect to the housing. A bottom block is configured to flatten fins on a second surface of the finned tube when the press arm is rotated and moves the top block downwardly. A tube stay clamping assembly includes a clamping housing configured to receive a tube stay having a top, bottom, rear, and front walls, the tube stay being configured to receive a flattened portion of the finned tube. A clamping arm is connected by linking arms to a clamping block, the clamping block configured to engage and force the front wall into snap-fit engagement with the top wall of the tube stay.

A thermal management system and method includes a body having an inlet and an outlet configured to direct a first fluid into and out of the body. The body incudes a channel that is fluidly separate from the inlet and the outlet. A second fluid is directed through the channel. A conduit assembly is fluidly coupled with the inlet and the outlet. The conduit assembly includes plural fluidly separate conduits. Each of the plural conduits extend between a corresponding first end and a corresponding second end along a corresponding tortuous path. The plural conduits are intertwined with each other between the first ends and the second ends. The plural conduits are positioned such that the second fluid flowing through the channel passes over the plural conduits and exchanges thermal energy with the first fluid that moves within each of the plural conduits.

An heat exchanger and method for forming the heat exchanger, the heat exchanger including a cooling architecture comprising at least one unit cell having a set of walls with a thickness, the set of walls defining fluidly separate conduits having multiple openings, each of the multiple openings having a hydraulic diameter, wherein an average fluid temperature (T.sub.f) to material temperature limit (T.sub.m) ratio (T.sub.f/T.sub.m) is greater than 0 and less than or equal to 1.25 (0<T.sub.f/T.sub.m≤1.25), and wherein the thickness (t) and the hydraulic diameter (D.sub.H) relate to each other by an equation:

[00001]$\frac{T_f}{T_m}.Math.\frac{D_H^{2/3}\left(D_H+t\right)}{{\left(D_H+2t\right)}^{8/3}}$

to define a unit cell performance factor (UCPF).