In some implementations, an exhaust gas recirculation cooler may include a shell defining an internal chamber; a first tube support plate defining a first wall of the internal chamber; a second tube support plate defining a second wall of the internal chamber; a plurality of cooling tubes extending through the internal chamber from the first tube support plate to the second tube support plate, the plurality of cooling tubes being flexible tubes; and at least one separator plate, extending within the internal chamber between the first tube support plate and the second tube support plate, that partitions the internal chamber such that a first set of the plurality of cooling tubes are to a first side of the at least one separator plate and a second set of the plurality of cooling tubes are to a second side of the at least one separator plate.

In some implementations, an exhaust gas recirculation cooler may include a shell defining an internal chamber; a first tube support plate defining a first wall of the internal chamber; a second tube support plate defining a second wall of the internal chamber; a plurality of cooling tubes extending through the internal chamber from the first tube support plate to the second tube support plate, the plurality of cooling tubes being flexible tubes; and at least one separator plate, extending within the internal chamber between the first tube support plate and the second tube support plate, that partitions the internal chamber such that a first set of the plurality of cooling tubes are to a first side of the at least one separator plate and a second set of the plurality of cooling tubes are to a second side of the at least one separator plate.

Iron-based braze filler alloys having unexpectedly narrow melting temperature ranges, low solidus and low liquidus temperatures, as determined by Differential Scanning calorimetry (DSC), while exhibiting high temperature corrosion resistance, good wetting, and spreading, without deleterious significant boride formation into the base metal, and that can be brazed below 1,100 C contains a) nickel in an amount of from 0% to 35% by weight, b) chromium in an amount of from 0% to 25% by weight, c) silicon in an amount of from 4% to 9% by weight, d) phosphorous in an amount of from 5% to 11% by weight, e) boron in an amount of from 0% to 1% by weight, and f) the balance being iron, the percentages of a) to f) adding up to 100% by weight. The braze filler alloys or metals have sufficient high temperature corrosion resistance to withstand high temperature conditions of Exhaust Gas Recirculation Coolers.

Iron-based braze filler alloys having unexpectedly narrow melting temperature ranges, low solidus and low liquidus temperatures, as determined by Differential Scanning calorimetry (DSC), while exhibiting high temperature corrosion resistance, good wetting, and spreading, without deleterious significant boride formation into the base metal, and that can be brazed below 1,100 C contains a) nickel in an amount of from 0% to 35% by weight, b) chromium in an amount of from 0% to 25% by weight, c) silicon in an amount of from 4% to 9% by weight, d) phosphorous in an amount of from 5% to 11% by weight, e) boron in an amount of from 0% to 1% by weight, and f) the balance being iron, the percentages of a) to f) adding up to 100% by weight. The braze filler alloys or metals have sufficient high temperature corrosion resistance to withstand high temperature conditions of Exhaust Gas Recirculation Coolers.

A plurality of upper fins and a plurality of lower fins are each provided in an EGR passage so as to be adjacent to each other across a predetermined space in a direction perpendicular to an exhaust-gas flow direction. The upper fins and the lower fins are gradually narrowed in width toward their respective projection directions, so that both sides thereof in their width direction have inclined surfaces. A tilt angle of the inclined surfaces of the lower fins is made larger than a tilt angle of the inclined surfaces of the upper fins.

A plurality of upper fins and a plurality of lower fins are each provided in an EGR passage so as to be adjacent to each other across a predetermined space in a direction perpendicular to an exhaust-gas flow direction. The upper fins and the lower fins are gradually narrowed in width toward their respective projection directions, so that both sides thereof in their width direction have inclined surfaces. A tilt angle of the inclined surfaces of the lower fins is made larger than a tilt angle of the inclined surfaces of the upper fins.

An injection structure using integrated exhaust heat recovery system (EHRS) condensate, the structure including an integrated heat exchange part connected to an engine of a vehicle and branched from an exhaust outlet of an exhaust manifold to integrate exhaust gas recirculation (EGR) and EHRS, a condensate circuit part extended from a rear end of the integrated heat exchange part to the engine of the vehicle and configured to move exhaust gas condensate, a three-phase valve configured to open and close so that a low-temperature coolant is selectively introduced into the integrated heat exchange part according to operating conditions, an EGR valve configured to open and close so that EGR gas with filtered condensate flows into the engine of the vehicle, a bypass valve fluidly connected to an exhaust muffler, and a controller configured to control opening and closing of the three-phase valve, the EGR valve, and the bypass valve according to the operating conditions.

An injection structure using integrated exhaust heat recovery system (EHRS) condensate, the structure including an integrated heat exchange part connected to an engine of a vehicle and branched from an exhaust outlet of an exhaust manifold to integrate exhaust gas recirculation (EGR) and EHRS, a condensate circuit part extended from a rear end of the integrated heat exchange part to the engine of the vehicle and configured to move exhaust gas condensate, a three-phase valve configured to open and close so that a low-temperature coolant is selectively introduced into the integrated heat exchange part according to operating conditions, an EGR valve configured to open and close so that EGR gas with filtered condensate flows into the engine of the vehicle, a bypass valve fluidly connected to an exhaust muffler, and a controller configured to control opening and closing of the three-phase valve, the EGR valve, and the bypass valve according to the operating conditions.

An exhaust gas heat transfer unit is disclosed having a heat exchanger including a bypass duct, an inflow diffuser with an exhaust gas inlet, and an outflow diffuser with an exhaust gas outlet. The heat exchanger and the bypass duct are assigned a control apparatus which diverts the exhaust gas flow through the heat exchanger and/or the bypass duct.

An exhaust gas heat transfer unit is disclosed having a heat exchanger including a bypass duct, an inflow diffuser with an exhaust gas inlet, and an outflow diffuser with an exhaust gas outlet. The heat exchanger and the bypass duct are assigned a control apparatus which diverts the exhaust gas flow through the heat exchanger and/or the bypass duct.