A heat exchanger for exchanging heat between a first medium and a second medium has a body comprising a pair of header plates, a pair of distribution plates, and a pair of case body lateral panels. Input and output header plates have a plurality of orifices, with a flow path assembly extending between each input header plate orifice and the corresponding output header plate orifice. Each flow path assembly includes at least one chamber assembly, having a corresponding medium directing component, disposed between a pair of tubular segments. Input and output distribution plates have a plurality of orifices. A first medium inlet side tank engages with the input header, a first medium output side tank engages with the output header plate, a second medium inlet side tank engages with the input distribution plate, and a second medium output side tank engages with the output distribution plate.

Various methods and systems are provided for an exhaust gas recirculation cooler including a plurality of cooling tubes. In one example, an exhaust gas recirculation (EGR) cooler includes a plurality of cooling tubes positioned within a housing of the EGR cooler, each cooling tube of the plurality of cooling tubes extending between and directly coupled to tube sheets of the EGR cooler at ends of each cooling tube, where at least one end of one or more cooling tubes of a first portion of the plurality of cooling tubes, inward of a tube sheet coupled to the at least one end, includes a compliant region, where the first portion is positioned proximate to an exhaust inlet of the EGR cooler.

Methods and systems are provided for an EGR system including an EGR cooler module directly mounted to a cylinder head. In one example, the EGR cooler module includes an EGR inlet port, an EGR outlet port, a coolant inlet port, and a coolant outlet port all arranged parallel with each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head. In another example, the EGR cool module includes an EGR inlet port and a coolant inlet port parallel to each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head, while also including an EGR outlet port and a coolant outlet port to interface with passages external to the cylinder head.

Methods and systems are provided for an EGR system including an EGR cooler module directly mounted to a cylinder head. In one example, the EGR cooler module includes an EGR inlet port, an EGR outlet port, a coolant inlet port, and a coolant outlet port all arranged parallel with each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head. In another example, the EGR cool module includes an EGR inlet port and a coolant inlet port parallel to each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head, while also including an EGR outlet port and a coolant outlet port to interface with passages external to the cylinder head.

A heat transfer apparatus includes an outer shell, an internal core body, and a flexible diaphragm extending from the core body to an interior surface of the outer shell. The shell includes a first inlet that receives a first fluid, a second inlet that receives a second fluid, a first outlet through which the first fluid exits the shell, and a second outlet through which the second fluid exits the shell. The core body forms first interior passageways that fluidly couple the first inlet with the first outlet and second interior passageways that fluidly couple the second inlet with the second outlet. The flexible diaphragm forms a flexible transition between each of the first inlet and the second inlet of the shell and the core body, and forms a seal that prevents the first fluid in the first interior passageways from flowing into the second interior passageways.

Methods and systems are provided for exhaust flow in an engine system including a split-exhaust manifold for expediting exhaust catalyst light-off and engine warm-up while reducing condensation in the engine system. In one example, a method may include, before exhaust catalyst light-off, flowing all or more exhaust gases, via a first exhaust valve and a first exhaust manifold, to an exhaust catalyst by passing a heat exchanger. Further, after light-off but before engine coolant warms up to a threshold temperature, all or more exhaust may be delivered to the heat exchanger, via a second exhaust valve and a second different manifold, prior to flowing to the exhaust catalyst; and exhaust gas recirculation may not be provided until the coolant reaches the threshold temperature to reduce condensation.

Methods and systems are provided for exhaust flow in an engine system including a split-exhaust manifold for expediting exhaust catalyst light-off and engine warm-up while reducing condensation in the engine system. In one example, a method may include, before exhaust catalyst light-off, flowing all or more exhaust gases, via a first exhaust valve and a first exhaust manifold, to an exhaust catalyst by passing a heat exchanger. Further, after light-off but before engine coolant warms up to a threshold temperature, all or more exhaust may be delivered to the heat exchanger, via a second exhaust valve and a second different manifold, prior to flowing to the exhaust catalyst; and exhaust gas recirculation may not be provided until the coolant reaches the threshold temperature to reduce condensation.

A system for recycling exhaust heat from an internal combustion engine is based on a recycling type of circulating a working fluid using the exhaust heat from the internal combustion engine. The system may include an EGR line configured to circulate a portion of exhaust gas generated from the internal combustion engine to an intake side, a working fluid circulation line configured to rotate a turbine with a working fluid vaporized by heat transferred from the EGR line, and an EGR side heat exchange unit configured to thermally connect the EGR line to the working fluid circulation line to cool an EGR gas by transferring heat from the EGR gas to the working fluid.

A system for recycling exhaust heat from an internal combustion engine is based on a recycling type of circulating a working fluid using the exhaust heat from the internal combustion engine. The system may include an EGR line configured to circulate a portion of exhaust gas generated from the internal combustion engine to an intake side, a working fluid circulation line configured to rotate a turbine with a working fluid vaporized by heat transferred from the EGR line, and an EGR side heat exchange unit configured to thermally connect the EGR line to the working fluid circulation line to cool an EGR gas by transferring heat from the EGR gas to the working fluid.

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.