A heat exchanger including a first header and a second header; a plurality of flat pipes, each defining a first end connected with the first header and a second end connected with the second header. The plurality of flat pipes are arranged and spaced apart from each other in axial directions of the first and second headers. Each of a plurality of fins is disposed between adjacent flat pipes. The plurality of fins includes first to third fins, in which the heat exchanger has a bending segment and a straight segment adjacent to the bending segment. The first fin is in the straight segment, the second and third fins are in the bending segment, a width of the second fin is larger than a width of the third fin, and the second and third fins are alternately arranged in the axial directions.

An apparatus for inserting flattened tubes into heat exchanger fins includes a guide inserted into at least one out of a plurality of cutaway portions for holding heat exchanger fins in the thickness direction. A guide holding unit holds the heat exchanger fins and the guide with a flattened tube holding unit in which flattened tubes are held in an intermittent arrangement with respect to the cutaway portions into which the guide has not been inserted. A flattened tube insertion driving unit inserts the flattened tubes held on the flattened tube holding unit into the cutaway portion with a platen that is caused to contact another edge in a width direction of the heat exchanger fins when the flattened tubes are inserted into the cutaway portions. Thereafter a compressing unit compresses the heat exchanger fins in the stacking direction.

An apparatus for inserting flattened tubes into heat exchanger fins includes a fin stack arranging unit in which heat exchanger fins are stacked in the thickness direction and a guide is inserted into at least a cutaway portion. A flattened tube arranging unit holds flattened tubes in an intermittent arrangement with respect to the cutaway portions into which the guide has not been inserted. A flattened tube insertion driving unit inserts the flattened tubes into the cutaway portions. A contact plate produces a reactive force when the flattened tubes are inserted into the cutaway portions. A flattened tube intermittently inserted fin stack arranging unit aligns the positions of cutaway portions into which the flattened tubes have not been inserted to the positions of the flattened tubes on the flattened tube arranging unit and is used in place of the fin stack arranging unit.

A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

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.

Hairpin-shaped heat exchanger tubes are guided with respect to a fin stack in which through-holes are formed in three or more lines. A guide apparatus includes: a first guide portion provided with a plurality of first guide pins that extend in an inclined direction; a second guide portion provided with a plurality of second guide pins that extend in an inclined direction in an opposite direction; a first guide pin axial direction moving apparatus that moves the first guide portion along an axial direction; a second guide pin axial direction moving apparatus that moves the second guide portion along an axial direction; a first guide pin row direction moving apparatus that moves the first guide portion along the row direction; and a second guide pin row direction moving apparatus that moves the second guide portion along the row direction. The hairpin-shaped heat exchanger tubes are held in gaps between the first guide pins and the second guide pins.

A heat exchanger may be manufactured using an apparatus which includes a rotating body configured to be disposed at one side of heat exchange fins having an insertion groove having one side formed to be depressed and placed to be downwardly directed to be rotatable. An inner side of the insertion groove of transferred heat exchange fins are seated on the rotating body. The apparatus also include a rotating blade configured to be connected to the rotating body to be rotatable together with the rotating body. The rotating blade supports the other side of the heat exchange fins to prevent the heat exchange fins from being deviated from the rotating body.

A heat exchanger and methods of manufacturing and assembling a heat exchanger, and more particularly to an air-flow heat exchanger having a mechanically assembled header for use in a motor vehicle. The heat exchanger comprises an all-metal bonded matrix including a plurality of substantially parallel metallic tubes and a plurality of metallic fins. The tubes have a heat transfer portion that is elongate in cross-sectional shape, and which comprises two opposing, longer sides, and two opposing shorter sides. At least one of the tubes is mechanically joined at a first end portion thereof to a first header of the heat exchanger by at least one compliant member. The compliant member extends around the first end portion of the tube to provide a seal and to permit relative movement between the mechanically joined tube and the first header due to thermal expansion and contraction of the matrix.

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.

An air intake separator system includes a plurality of vanes adapted to remove fluid or precipitation from an air stream, wherein the vanes are operably coupled to tubular rods with an interference fit. Applying an elevated temperature heat transfer fluid to the plurality of vanes removes fluid or precipitation from an air stream in order to prevent ice formation. Likewise, applying a lower temperature heat transfer fluid can cool the vanes.