A heat recovery wheel for a heat exchanger includes a wheel rim defining an outer perimeter of the heat recovery wheel, and a plurality of wheel passages located between the wheel rim and the wheel axis. The plurality of wheel passages are arranged in a plurality of radial layers relative to a wheel central axis. Each layer is defined by a first shaped material having a first cross-sectional shape and a second shaped material assembled to the first shaped material, the second shaped material having a second cross-sectional shape. Radially adjacent layers of the plurality of layers are secured directly to one another, and the plurality of wheel passages are configured for flow of a first airflow and a second airflow therethrough for thermal energy exchange between the first airflow and the second airflow.

A metallic honeycomb body with channels through which a gas may flow, made up of layers of at least partially structured sheet metal, the layers of sheet metal having at least in subregions at least two different structures, of which the first structure, with a greater structure height (H), determines the size of the channels and the second structure has a much smaller structure height (h) between troughs and peaks and the form and/or the structure height (H) of the second structure being chosen such that a ceramic coating applied later may fill the troughs of the second structure on average to at least 10%, in particular at least 50%, of their structure height (h). With the honeycomb body according to the invention, more coating material per unit of volume is durably attached in a metallic honeycomb body without excessively increasing the pressure loss. This is of advantage particularly for applications for reducing nitrogen oxides (NOx) in diesel exhaust gases.

A metallic honeycomb body with channels through which a gas may flow, made up of layers of at least partially structured sheet metal, the layers of sheet metal having at least in subregions at least two different structures, of which the first structure, with a greater structure height (H), determines the size of the channels and the second structure has a much smaller structure height (h) between troughs and peaks and the form and/or the structure height (H) of the second structure being chosen such that a ceramic coating applied later may fill the troughs of the second structure on average to at least 10%, in particular at least 50%, of their structure height (h). With the honeycomb body according to the invention, more coating material per unit of volume is durably attached in a metallic honeycomb body without excessively increasing the pressure loss. This is of advantage particularly for applications for reducing nitrogen oxides (NOx) in diesel exhaust gases.

An elongate profile having a first portion and a second portion, the first and second portions being joined together at a first joining portion, the first and second portions being non collinear, the joining portion comprising an array of raised or rebated formations, each formation extending across the joining portion in a direction which is non-parallel to the principal axis of the profile and flat lands being provided between successive formations in an array and the pitch between successive formations in an array being from 2 to 20 times, for example from 5 to 15 times, the thickness of the flatlands.

An elongate profile having a first portion and a second portion, the first and second portions being joined together at a first joining portion, the first and second portions being non collinear, the joining portion comprising an array of raised or rebated formations, each formation extending across the joining portion in a direction which is non-parallel to the principal axis of the profile and flat lands being provided between successive formations in an array and the pitch between successive formations in an array being from 2 to 20 times, for example from 5 to 15 times, the thickness of the flatlands.

A tube for a heat exchanger includes a tube outer body enclosing a tube inner volume, and a corrugated insert received within the tube inner volume. The tube outer body has a pair of broad planar walls joined by arcuate end walls. The corrugated insert defines flow channels through the tube, with opening in flanks of the insert allowing for flow communication between adjacent flow channels. Bypass channels adjacent the arcuate end walls are fluidly isolated from the adjacent flow channels by the absence of such openings in the end flanks. Flow through the bypass channels is obstructed by flow blocks at one or both ends of the bypass channels.

A tool for manufacturing blanks and a process for stacking and destacking the blanks in a production line are provided. The tool is incorporated into a blanking die used to trim a metal sheet and form the blanks. When the blanks are stacked, the destacking formations provide gaps between the adjacent blanks. The gaps provide an entry to blast air and thus reliably separate the blanks for pick up, so that only one blank is picked up at a time. The tool includes a deforming unit that has an engagement element for pressing deformations into the metal sheet. The deformations are pressed adjacent to at least one edge of the metal sheet so that when the metal sheet is trimmed, and the blanks are stacked, they are spaced by the deformations by adjacently stacked blanks.

A tool for manufacturing blanks and a process for stacking and destacking the blanks in a production line are provided. The tool is incorporated into a blanking die used to trim a metal sheet and form the blanks. When the blanks are stacked, the destacking formations provide gaps between the adjacent blanks. The gaps provide an entry to blast air and thus reliably separate the blanks for pick up, so that only one blank is picked up at a time. The tool includes a deforming unit that has an engagement element for pressing deformations into the metal sheet. The deformations are pressed adjacent to at least one edge of the metal sheet so that when the metal sheet is trimmed, and the blanks are stacked, they are spaced by the deformations by adjacently stacked blanks.

A wave rolling assembly and a process for manufacturing a component for a vehicle using the wave rolling assembly is provided. The process includes conveying a metal coil through a first leveler to present a metal sheet, and conveying the metal sheet through a looping pit. The metal sheet travels from the looping pit to the wave rolling assembly for forming a plurality of waves along the side edges of the metal sheet. The wave rolling assembly stretches the metal sheet. The wave rolling assembly can include a die assembly or a roll forming apparatus. The metal sheet is then conveyed through a second leveler to flatten the metal sheet. The metal sheet is cut into blanks and formed into the finished component in a blanking press and die assembly. Less scrap is generated due to the reduced thickness along the edges and overall increased width of the blanks.

A wave rolling assembly and a process for manufacturing a component for a vehicle using the wave rolling assembly is provided. The process includes conveying a metal coil through a first leveler to present a metal sheet, and conveying the metal sheet through a looping pit. The metal sheet travels from the looping pit to the wave rolling assembly for forming a plurality of waves along the side edges of the metal sheet. The wave rolling assembly stretches the metal sheet. The wave rolling assembly can include a die assembly or a roll forming apparatus. The metal sheet is then conveyed through a second leveler to flatten the metal sheet. The metal sheet is cut into blanks and formed into the finished component in a blanking press and die assembly. Less scrap is generated due to the reduced thickness along the edges and overall increased width of the blanks.