A heat exchanger having an optimum design considering a thermal capacity of an end portion of an extrusion tube to significantly improve heat transfer performance by optimizing a shape and a thickness of the end portion of the tube, and a heat exchanger having an optimum design obtained based on a structured rule to enable easy application to other tubes with various dimensions. The heat exchanger has an end portion of a tube has a cross section in a quadrangular shape with rounded corners, each having a radius in a range of 15% to 45% of a height of the tube.

A flow manifold for a heat exchanger core includes a number of fractal flow splitters arranged in a grid pattern of layers each fluidly connected to a corresponding first circuit layer, a flow plenum having a number of flow channels that are fluidly connected to an associated fractal flow splitter, one or more flow dividing vanes located in each flow channel thereby dividing the associated flow channel into two or more sub-channels, and an outer manifold surrounding the fractal flow splitters and configured to direct a first circuit flow into or out of the heat exchanger core. Each fractal flow splitter has an open end and a plenum end, and provides a transition from the open end to the flow plenum.

A heat exchanger for a water heater having a burner includes an outer tube extending longitudinally along a centerline from a first end adjacent the burner to a second end. Indentations are formed along the length of the outer tube and extend towards the centerline. An inner member extends through the outer tube and between the indentations such that flue gases from the burner flow in a passage between the inner member and the outer tube from the first end to the second end of the outer tube.

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.

A tube for a thermal transfer device can include a wall having a length and having an inner surface and an outer surface, wherein the inner surface forms a cavity. The tube can also include at least one first dimple pressed into the wall toward the cavity at a first location along the length of the wall, where the inner surface of the wall at the at least one first dimple is separated from itself by a first distance. The tube can further include at least one second dimple pressed into the wall toward the cavity at a second location along the length of the wall, where the inner surface of the wall at the at least one second dimple is separated from itself by a second distance. The cavity can be configured to receive a fluid that flows continuously along a length of the at least one wall.

A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled where each hot core plate is directly interlocked to at least one cold core plate. A wax pattern is formed with the core assembly with an external shell formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material. Once the molten material has solidified, the external shell and the core are removed.

A heat exchanger includes a heat exchanger body having a first end and a second end opposed to the first end along a flow axis. A plurality of flow channels is defined in the heat exchanger body extending axially with respect to the flow axis. A first set of the flow channels forms a first flow circuit and a second set of the flow channels forms a second flow circuit that is in fluid isolation from the first flow circuit. Each flow channel is fluidly isolated from the other flow channels. The flow channels all conform to a curvilinear profile.

A heat exchanger includes a header and a plurality of heat exchange tubes. The header includes a first tube and a second tube spaced apart from each other. The heat exchange tube includes a first section, a processing section and a second section. The processing section is connected between the first section and the second section. A processing method for a heat exchanger includes: twisting the processing section relative to the first section and the second section in a length direction of the first tube; bending the first section and the second section relative to the processing section; and pushing the processing section by a predetermined distance in the same direction as a direction in which the processing section is twisted.

The present disclosure provides a collecting tube and a heat exchanger having the same. The collecting tube includes a housing provided with a plurality of collecting channels, wherein the plurality of collecting channels are disposed at intervals; wherein the housing is further provided with a plurality of connecting portions, and the plurality of connecting portions are disposed at intervals; and the plurality of connecting portions are in one-to-one correspondence to the plurality of collecting channels, each of the plurality of connecting portions communicates with a corresponding one of the collecting channels, and the plurality of connecting portions are communicated with heat exchange flat tubes.

A core body includes a structure having a plurality of connected unit cells. At least one unit cell has one or more sidewalls that are curved and define a portion of an inner passageway within and through the unit cell. The one or more sidewalls define multiple orifices and include a cone disposed between at least some of the orifices. A dimple is defined along an outer surface of the unit cell at the cone. The outer surface at least partially defines an outer passageway that is sealed from the inner passageway by the one or more sidewalls. The one or more sidewalls are configured to transport one or more of thermal energy from a first fluid or a component of the first fluid flowing in the inner passageway to a second fluid flowing in the outer passageway without the first fluid mixing with the second fluid.