A baffle for a thermal transfer device can include a body having a multiple first apertures that traverse therethrough, where each first aperture has a first outer perimeter that includes a first base shape and at least one first protrusion extending from the first base shape. Each of the first apertures is configured to receive a tube. The first base shape of each first aperture has a first shape and a first size that is configured to be substantially the same as the first shape and the first size of an end of a tube.

A tube bundle assembly includes at least one tube and a baffle. The baffle includes at least one hole for receiving the at least one tube. The at least one hole has a non-uniform diameter such that only a portion of a periphery of the at least one hole is positionable in contact with the at least one tube.

An engine includes: two cylinder rows so placed as to be aligned side by side; a turbocharger; and an intercooler shared by the two cylinder rows, and connected to the turbocharger. The intercooler has: a cool liquid flow path through which a cool liquid flows, and an intake air flow path through which intake air from the turbocharger flows. The cool liquid flow path has an inlet and outlet of the cool liquid on one side in a first direction along the flow of the cool liquid. The intake air flow path has an inlet of the intake air on one side in a second direction along the flow of the intake air, and an outlet of the intake air on another side.

A baffle for a thermal transfer device can include a body having a multiple first apertures that traverse therethrough, where each first aperture has a first outer perimeter that includes a first base shape and at least one first protrusion extending from the first base shape. Each of the first apertures is configured to receive a tube. The first base shape of each first aperture has a first shape and a first size that is configured to be substantially the same as the first shape and the first size of an end of a tube.

A heat exchanger includes a body portion and a pair of end plates at least partially forming an enclosure with the body portion. A plurality of tubes extend through at least one of the body portion and the pair of end plates. At least one tube sheet includes a plurality of openings with a corresponding one of the plurality of tubes located in one of the plurality of openings. The tube sheet is made of a material which expands in the presence of refrigerant.

A heat exchanger includes a sensor grid with sensor leads extending through tube restraints for heat exchange tubes in the heat exchanger. The tube restraint includes a body having a plurality of tube openings defined therein with each tube opening receiving one heat exchange tube of the set of heat exchange tubes therethrough. The body also includes a sensor lead opening defined therein to receive a sensor lead therethrough. Each tube opening has a larger dimension than the sensor lead opening. The sensor grid is installed during manufacture rather than in the field, allowing the sensor grid to be on outermost and inner sets of heat exchange tubes in the heat exchanger.

A heater assembly includes a flow guide and a plurality of electrical resistance heating elements. The flow guide defines a continuous geometric helicoid disposed about a longitudinal axis of the heater assembly. The flow guide defines a predetermined pattern of perforations that extend in a longitudinal direction through a first longitudinal length of the geometric helicoid. The longitudinal direction is parallel to the longitudinal axis. The geometric helicoid has a first pitch at a first zone along the longitudinal axis and a second pitch at a second zone along the longitudinal axis. The second pitch is shorter than the first pitch. The electrical resistance heating elements extend through the perforations.

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 heater assembly includes a flow guide and a plurality of electrical resistance heating elements. The flow guide defines a continuous geometric helicoid disposed about a longitudinal axis of the heater assembly. The flow guide defines a predetermined pattern of perforations that extend in a longitudinal direction through a first longitudinal length of the geometric helicoid. The longitudinal direction is parallel to the longitudinal axis. The geometric helicoid has a first pitch at a first zone along the longitudinal axis and a second pitch at a second zone along the longitudinal axis. The second pitch is shorter than the first pitch. The electrical resistance heating elements extend through the perforations.

A heat exchanger includes a first channel with at least one first wall for porting a first fluid and a second channel with at least one second wall for porting a second fluid. The heat exchanger includes a barrier chamber located between the at least one first wall and the at least one second wall such that a rupture of one of the at least one first wall and the at least one second wall does not result in mixing of the first fluid and the second fluid. The heat exchanger includes a support member that extends between the at least one first wall and the at least one second wall.