Patent ID: 7422054

Claim:
A heat exchanger for a high temperature charge air cooler receiving air heated to 600° F. or higher, said heat exchanger comprising: a plurality of unitary tubular aluminum heat exchange modules of a generally rectangular cross section, each module having at least one longitudinal through bore between opposite outer face portions which face portions are joined by opposite edge faces, said face portions provided with a plurality of grooves extending parallel to the through bore; the outer face portions along substantially the full length of the module having formed therein slots that extend perpendicular to the through bore between said edge faces, said slots defining narrow heat exchange fins, said fins having a toothed shape, the endmost fin at each end of the module having a greater thickness than the fins therebetween and terminating adjacent a neck that surrounds and defines an end opening to said through bore, the neck having a wall thickness of at least about 0.090 in. (2.3 mm); said plurality of modules arranged with the face portions of adjacent modules in juxtaposition; an aluminum header plate for each end of said plurality of modules, each header plate having a plurality of openings defined by flanges and sized to receive the necks of the modules and to interconnect and hold the same in an assembly, the flanges having a wall thickness of at least about 0.090 in. (2.3 mm), each header plate supported on an endmost fin and closing the space defined by the tooth shaped fins between the necks of adjacent modules, and each header plate having a peripheral edge generally coincident with the outer periphery of the assembly; and, fused aluminum joints formed substantially equally from neck material and flange material, said joints providing air tight seams between each flange and the respective neck extending therethrough and connecting each header plate to the assembly.