KR100193961B1 - Aluminum Charge Air Cooler and Manufacturing Method - Google Patents

Abstract

The header plates 26 and 28 are formed of a channel having a central web 80 having angles 82 and 84 formed on the side thereof, and are occupied by a configuration in which a long hole 86 for receiving an end of the tube 36 is formed. Fatigue or stress associated with heat and pressure in the header plates 26 and 28 of the air cooler is excluded. Peripheral flanges 88, 90, 92 and 94 are formed in the long holes 86 extending between the corner portions 82 and 84, and are substantially surrounded by round cam surfaces 96 and 98 on the opposite sides.

Description

Aluminum Charge Air Cooler and Manufacturing Method

1 is a side view of a heat exchanger, in particular a charge air cooler, produced according to the invention and having the same appearance as a conventional charge air cooler.

2 is a partial perspective view of a header plate made according to the prior art.

3 is a partial perspective view similar to that of FIG. 2 of a further improved header plate according to the prior art.

4 is a partial perspective view similar to FIGS. 2 and 3 of a header plate made in accordance with the present invention.

5 is a cross-sectional view taken along line 5-5 of FIG.

6 is a sectional view taken along line 6-6 of FIG.

7 is a sectional view taken along line 7-7 of FIG.

8 is a partial bottom view of the header.

9 is a partial plan view of an intermediate state in the construction of a header.

10 is a perspective view of a die or fixture usable in the formation of a header.

11 is an elevation view of a punch used with the die of FIG.

FIG. 12 is an elevation of the punch turned 90 ° with respect to FIG. 11. FIG.

13 is a flow diagram illustrating a process of the manufacturing method of the heat exchanger according to the present invention.

The present invention relates to heat exchangers, and in particular to heat exchangers suitable for use as so-called charge air coolers in aluminum heat exchangers and internal combustion engine systems.

For various reasons, the use of turbochargers is increasing in internal combustion engine systems. As is well known, the turbocharger comprises a turbine wheel driven by exhaust gas from the engine to drive a rotary compressor, the rotary compressor compressing the combustion air before the combustion air enters the combustion chamber of the internal combustion engine. This type of system recovers some of the energy consumed when incompletely consumed exhaust gas expands without work or exhibits a higher compression ratio than is achieved by the geometry of the internal combustion engine itself.

It is known that when the incoming combustion air is compressed by the turbocharger, it is simultaneously heated to reduce its density. Thus, the oxygen content for combustion per unit volume of hot air from the turbocharger at a given pressure is less than the content at the same volume of cold air at the same pressure. This limits the amount of fuel that can be combusted in a given operating cycle of the internal combustion engine, thereby limiting the output of the internal combustion engine. Thus, in particular in so-called vehicle applications, so-called charge air coolers are inserted between the compressor stages or between the compressor side of the turbocharger and the intake manifold (or equivalent) for the internal combustion engine. The hot combustion air from the turbocharger is sent to the engine through the charge air cooler, and at the same time the atmosphere passes through the charge air cooler in the flow path which is in heat exchange with the combustion air while being separated from the combustion air. Therefore, when the combustion air is cooled, the density of the combustion air is increased, thereby increasing the amount of oxygen to the charge air to the engine, thereby assisting combustion.

It can be easily seen that the charge air cooler operates in a relatively stressful environment even when the pressure of the combustion air causes a relatively small pressure difference from the atmosphere. The charge air cooler is typically employed in a vehicle, so that the vehicle is subject to great vibrations and shocks when traveling on the ground.

In addition, the charge air cooler is repeatedly heated and cooled during the heat cycle, that is, when the vehicle engine is turned on or off, as well as during operation during shifting. In a typical charge air cooler tank, a change in combustion air speed with a change in engine speed results in a high temperature gradient of 25 ° F. from one tube to the next, which stresses the header joint in the tube over time. Can be added.

Finally, as described above, a typical charge air cooler does not operate at the above-mentioned atmospheric pressure, but the charge air cooler needs to pass a large amount of combustion air to the engine with minimal resistance, and thus employs a large flow path formed with a relatively large surface area. do. When a very low pressure difference is applied over a large surface area, it can be seen that a significant force exists, which further stresses the components of the charge air cooler.

It is to solve the above problems of the present invention.

The primary object of the present invention is to provide a novel improved heat exchanger. In particular, it is an object of the present invention to provide a novel improved heat exchanger which can be used as a charge air cooler and a method of manufacturing the same.

In order to achieve the above object, according to one feature of the invention, (a) to install a fin and tube assembly having a solder coating at the interface between the parallel tube and a pin interposed therebetween, (b) A metal channel having a brazing coating on both sides, and (c) spaced apart in the web of the channel in the same shape as the cross section of the tube, spaced apart along the gap of the tube, and protruding in the direction of the channel from the web around the channel. Forming a header plate by forming a series of flanged long holes, (d) inserting a tube into each of the holes to assemble the header with the pin assembly located within the flange, and (e) the metal on the header opposite the pin and tube assembly. Assemble the tank and (f) the assembly obtained in step (e), wherein the pins are soldered to the tubes, the tubes are soldered to the flanges and the headers are kept in soldering conditions sufficient to solder the tanks. It provides a process for the production of a heat exchanger which comprises a.

In a preferred embodiment, the header, tube and tank are formed of aluminum.

In a more preferred embodiment, step (c) first forms a long hole in the web with a predetermined interval smaller than the cross section of the tube, and then drives the punch having a cross section similar to the cross section of the tube through the long hole. And a flange connected thereto.

Further, according to the present invention, the tube is a flat tube, the long hole extends between the respective parts, and at the end of the long hole the flange is in contact with the respective parts, so that the Makes it possible to minimize the depth.

Further, the present invention drives the punch at least partially rounded cam surface around each long hole opposite the flange to form a pilot face for mating the tube by cam in each long hole during the step (d). It is performed by forming.

According to another feature of the invention, (a) to install a fin and tube assembly consisting of a parallel tube and a pin interposed therebetween at a predetermined interval, (b) to install a channel having a corner portion spaced apart from the web, (c) forming a series of holes in the web of the channel spaced apart in the same shape as the cross section of the tube, spaced along the gaps of the tubes, with a flange formed in the direction of the channel from the web to the periphery of the channel, and also mating the tubes by the cam in the hole. A header plate is formed by forming a cam surface at least partially rounded around each of the long holes opposite the flange to form a pilot surface, and (d) the header plate formed in step (c) is brought into contact with the fin and tube assembly. They are inserted into each slot with or without guidance by first moving them towards each other and then first bringing the tube into contact with the round cam surface. And, (e) fixing the tank between each section of the channel and, (f) provides a method for producing a heat exchanger, characterized in that comprising the step of bonding the tube and the tank channel.

In a preferred embodiment of the present invention, step (f) is performed by soldering.

Further, according to another feature of the present invention, each of the elongated first and second tanks having a heat exchange fluid port and an opening for receiving a header plate, tapered to gradually decrease in cross section from each connected port, and spaced apart from each other, One pair of header plays, one for each tank, each formed by an elongated channel with flat central webs formed with portions spaced parallel to the sides, each portion of each header plate receiving the header plate of the combined tank. The web of each header plate comprises a plurality of long holes of predetermined intervals extending approximately between the respective parts corresponding to both sides of the opening, each hole having a flange around the web side on the same side as each part, The flange portion at the end of the abutment is approximately in contact with the connected corner portion, and each long hole is a web on the opposite side of the flange. A pair of headerplates at least partially surrounded by a round pilot surface for guiding the tube in the long hole and an end extending between the tank and mating with the long hole at an opposite end of the pair of headerplates. It provides a charge air cooler for an internal combustion engine comprising a plurality of parallel flat tubes having a predetermined interval and an S-shaped pin interposed between the adjacent tubes and bonded to the tubes.

In a more preferred embodiment, the heat exchanger is an air cooler for an internal combustion engine, and each tank is tapered so that the cross section is gradually smaller from the connected heat exchanger fluid port, and an S-shaped fin is interposed between adjacent tubes and joined to the tube.

In a more preferred embodiment, the header plate is aluminum and solder coated on both sides thereof, and the flange inner portion around each hole is formed on one side of the header plate and has a solder coating on the side, and the tube is formed of aluminum. Soldered to the header by solder coating from one side located inside the flange, the opposite side of each of the portions having a solder coating from the other side of the header plate, the tank being made of aluminum to solder on the other side of the header plate It is soldered to the header plate by a covering material.

Other objects and advantages of the present invention will become apparent from the following detailed description with reference to the accompanying drawings.

1 shows an embodiment of a heat exchanger manufactured according to the present invention in the form of a charge air cooler. However, the advantages of the present invention can be advantageously employed in heat exchangers used for other purposes than charge air coolers, and are not limited to charge air coolers within the scope defined in the claims. First, note that the charge air cooler shown in FIG. 1 is conventional except for considering the same header plate. Based on such a background, FIG. 1 is explained in full detail.

The charge air cooler preferably comprises opposing tanks 10, 12 formed of aluminum, the tanks 10, 12 having a lengthwise opening (s) with a length slightly shorter than the length of each tank 10 or 12. 14,16 are formed.

The tanks 10 and 12 have heat exchange fluid ports 18 and 20 extending rearward at their upper ends, as shown in FIG. 1. One of these ports 18 and 20 is an internal combustion engine. The other port is also connected to the outlet of the turbocharger formation of the system by the usual method on the inlet side of the internal combustion engine.

In order to minimize weight and provide adequate flow area for good flow distribution, each tank 10, 12 is tapered gradually from the coupling ports 18, 20 at reference numerals 22, 24. Thus, each internal cross-sectional area of each tank 10, 12 gradually decreases as the distance from the ports 18, 20 increases.

The openings 14, 16 of the tanks 10, 12 are completely covered by channel shaped header plates 26, 28. The header plates 26 and 28 may be formed identical to each other. Therefore, only one is described in the following description.

Between the header plates 26, 28, a fin and tube assembly, denoted by reference numeral 30, is disposed, which is comprised of three components, namely the side plates of the top and bottom surfaces of the assembly 30. 32, 34 and a plurality of parallelly extending flat tube 36 which is inserted between tanks 10 and 12 so as to be in fluid communication with the inside of tanks 10 and 12, extending between header plates 26 and 28; And S-shaped pins 38 located between adjacent tubes 36 or between one of the tubes 36 and adjacent side plates 32 and 34. It can be seen from FIG. 1 that the side plates 32 and 34 are formed to have a length shorter than the distance between the header plates 26 and 28.

Next, the description of the preferred embodiment of the present invention will be interrupted for a while, and the structure of the conventional header will be described. As described above, the headers 26 and 28 are formed as channels, so far, the same as the conventional header of the reference numeral 40 shown in FIG. The header 40 is provided with a flat center web 42 and two parallel corners 44 and 46 formed on the side surface of the center web 42. Within the web is a series of long holes 48 that are formed elongated in a direction extending between the corners 44 and 46 at a distance corresponding to the distance between the tubes 36. The longitudinal length of this long hole 48 is equal to the longitudinal length of the cross section of each tube 36. Here, in the conventional header 40, the end portion 50 at a distance such that a short distance is formed from the end portion 50 of the long hole 48 to the inner surface of each of the portions 44 and 46 indicated by the dotted lines 52 and 54, respectively. 50) is formed. In the normal case, the tube 36 is soldered into the long hole 48.

In the case of using the header 40 as part of the charge air cooler, the header 40 is subjected to a change in pressure on the surface between the corner portions 44 and 46, and such a structure is a web (around the periphery of each long hole 48). The area of 42 is curved similar to the diaphragm in response to the pressure change in the coupling tank 10 or 12. As a result, such bending occurs in the tube-header joint, making it unusable as a result of stress and fatigue.

In order to solve such a problem, conventionally, the header configuration indicated by reference numeral 60 in FIG. 3 is employed. Also in this case, the angle parts 64 and 66 parallel to the side surface of the flat center web 62 are formed. A long hole 68 formed long to receive the tube 36 extends between the legs 64, 66. In this case, however, the end 70 of the long hole extends to the inner surface of the corners 62 and 64, respectively, as indicated by dashed lines 72 and 74, respectively. That is, in the conventional structure of FIG. 3, the area of the web 42 between the end 50 of each long hole 48 and the inner surface 52 or 54 of the adjacent corner portion 44 or 46 is removed, and the second It will significantly reduce or eliminate the diaphragm bending effect seen in the structure of the figure.

However, the conventional arrangement of FIG. 3 also has other problems seen in the embodiment of FIG. 2, for example, the stiffness of the web 62 is smaller than desired. In addition, in order to solder the aluminum tube to the hole 68 or the hole 48, the brazing metal must flow from the surface of the web 62 or 42 around the corner to the hole 68 or 48 or the tube itself must be brazed. . In the former case, there is a high possibility that the joint is incompletely or weakly formed, and in the latter case, it is expensive because it is soldered over the entire length of all the tubes for use in soldering at the end thereof.

In addition, it is faced with another problem that assembly is difficult, and in practice, the pin and tube assembly 30 is formed and disposed in the fixture, and the header plate is positioned at both ends thereof to mate with the end of the tube 36. . One or both of the side plates 32 and 34 are subjected to lateral pressure toward the other side plate while relatively moving the header plates 26 and 28 through the combined end of the tube 36. The pressure is intended to sufficiently compress the pin and tube assembly 30 to mate the ends of the tube 36 so that they are easily inserted into the long holes 48 or 68 of the web 42 or 62. However, this process is rather cumbersome and there is a high tendency for tube-header joints to be improperly formed in a continuous soldering process if it is desired to speed up by expanding the hole to accommodate the end of the tube 36 more easily.

In view of the foregoing, the improved headers 26 and 28 of the present invention are described, and since the two headers 26 and 28 are the same as described above, only the header 26 will be described. 4 to 8, the headers 26 are formed with long portions 82 and 84 extending parallel to the sides of the flat web 80 in the center thereof. Typically the header 26 is made of aluminum and both sides are covered with a braze coating.

The long hole 86 is located in the web 80 and extends between the corners 82 and 84. As shown in FIGS. 5 and 6, the periphery of each long hole 86 is completely surrounded by flanges 88, 90, 92, 94 located between the corners 82, 84. FIG. As shown in FIG. 5, the flanges 88, 90, 92, 94 have two elongated flanges 88, 90, and as shown in FIG. 6, the flanges 88, 90 have rounded end flanges. (92,94) connected to form a continuous single flange (88,90,92,94) as shown in FIG. 8, the end flanges (92,94) of the flange being adjacent corners (82) , 84). As such, the long hole 86 has a length that minimizes or eliminates the diaphragm effect as in the long hole 68. In addition, the corner depth is maximized by extending the long hole 86 to the point where the flanges 92,94 abut the corresponding angles 82,84 for any given tank and / or header size. In most cases, this will increase efficiency without increasing core surface area. In addition, the flanges 88, 90 perpendicular to the plane of the web 80 impart mutual stiffness to improve the stiffness of the web on the conventional headers 40, 60 shown in FIGS.

In addition to providing flanges 88, 90, 92, and 94 around each of the long holes 86, long members formed along the longitudinal direction of the long holes 86 on opposite sides of the parts 82, 84 of the web 80. The long hole 86 is at least partially surrounded by a round cam surface composed of an 96 and an end member 98 formed at the end of each long hole 86. The cam faces 96 and 98 are located on the tube receiving side of the header 86, whereby when the header and tube are moved relative to each other, the mismatched tubes are brought into flanges by mating into the long holes 86 by the cam in contact with the cam surface. Engage with the inner surface 100 of (88,90,92,94). This inner surface 100 is constructed very similar to the outer shape of the end of the tube 36, so that a good solder joint is achieved.

The method of forming the header 26 is shown in FIGS. 9-12. The channel can be formed by die-casting the aluminum sheet soldered on both sides, the long hole 110 is formed in the web 80 in the center of the long hole 86, and the long hole 86 is finally It is formed in the web (80). As shown in FIG. 9, the long hole 110 is narrower than the long hole 86 and the length over the web is shorter than the long hole 86.

This channel is then placed in a fixture or die 111, as shown in FIG. The fixture shown in FIG. 10 has parallel slots 112 and 114 which receive corners 82 and 84, respectively. If necessary, the upper surface of the fixture 111 may include a pilot protrusion 116 that can be accommodated at the top of the long hole 110 to properly position the channel in the fixture 111.

A cross slot 118 is positioned at the center of the upper surface of the fixture 111 corresponding to the center of the long hole 86 to be formed as an end, and at the end of each slot 118, the relief is opposite to the parallel slot 112 or 114. 120 is formed. The relief 120 has a width approximately equal to the width of each slot 118, the length of which is about one half the depth of each slot of the parallel slots 112, 114.

Also, in forming the long hole 86, a punch as indicated by reference numeral 122 in FIGS. 11 and 12 is used. The punch has an end portion 124 including a central flat portion 126, and bevels 128 are formed on all four sides thereof. The bevel 128 is connected to the punch portion 130 having the same configuration or shape as the inner surface 100 of the flanges 88, 90, 92, 94. The punch portion 130 is also connected to a slightly concave bevel, i.e., an inner circular portion 132 of the same shape as the cam faces 96 and 98, and then the circular portion 132 is connected to the remaining portion 134 of the punch. .

Considering that the long hole 110 is smaller than the long hole 86, when the channel is disposed in the punch acting by the fastener 111 and the long hole 110, it surrounds each long hole 110 and punches 130 The material within the range of c) deforms to form the flanges 88, 90, 92, 94. When the punch 122 is fully inserted into the slot 118, the circular portion 132 is in contact with the top surface of the web 80 to form round cam surfaces 96 and 98 surrounding each long hole 86. Typically, punch 122 is sized such that some or all flanges 88, 90, 92, 94 in a single header plate are formed simultaneously.

In fact, by the formation of the flanges 88, 90, 92, 94 of this type, an external force is applied to the areas of the flange portions 92, 94, so that the outer surfaces of the corner portions 82, 84 are shown in FIG. It becomes slightly convex as in reference numeral 140. However, these convex portions are directed into the relief 120 of the fixture 111, as a result of which the header forming the wedge can be avoided.

FIG. 13 is a flowchart illustrating a method of manufacturing a heat exchanger such as a charge air cooler according to the present invention. Steps 140 and 142 represent a step of forming a header as described above. These steps represent the formation of an aluminum channel with solder coating and initial slotted webs on both sides and a flange plate formed by punching around the slots to form a header plate. Another initial step of the present invention is shown in step 144, which is between the side plates 32 and 34, the tube 36 and the tube 36, or between the tube 36 and the side plates 32 and 34. A step of forming a fin and tube assembly 30 consisting of S-shaped fins 38 located between one side plate is shown. This step is done by alternately stacking the tubes and fins as in conventional methods, and then using the appropriate fixtures to hold the tubes and fins in an assembly relationship.

In the usual case, the tube 36 is formed of aluminum and the fins 38 are also formed of aluminum. In general, the tube 36 is injection molded. Typically the fin is formed of an aluminum braze sheet to provide the braze metal needed to join the tube 36 and the side plates 32 and 34.

Also in the usual case the tube 36 is pre-installed with an internal turbulator, for example a lanced offset turbulator. When such a turbulator is installed, the tube often hits the turbulator prior to the soldering operation.

In step 146, the headers 26 and 28 are assembled to the pin and tube assembly 30, which is caused by the relative movement of the pin and tube assembly 30 and one header 26 relative to each other. By moving towards The end of the tube 36, which is fully mated with the corresponding long hole 86, is easily inserted into the long hole, and the mismatched end is guided into the corresponding long hole 86 in contact with the cam faces 96, 98. The tube end is inserted into the long hole 86 at least to the depth of the flange (88, 90, 92, 94). As is well known, fixtures may be used to hold the headers 26 and 28 assembled to the pin and tube assembly 30.

Next, step 148 is to assemble the tanks 10 and 12 and the headers 26 and 28, respectively. As shown in FIG. 1, the tanks 10 and 12 are positioned in a direction covering the entire header receiving openings 14 and 16 between the respective portions 82 and 84 of the respective headers 26 and 28. As shown in FIG. In addition, suitable fixtures may be used to hold the tank 10 assembled to the header.

Next, step 150 is to solder. In this soldering operation, the pin 38 is soldered to the tube 36, the tube ends are soldered to the flanges 88, 90, 92 and 94, and the respective parts 82 and 84 are soldered to the tanks 10 and 12. The tank-header-pin and tube assembly for sufficient time to be soldered to the tanks 10,12 adjacent to the ends of the openings 14, 16 at their ends with respect to the side of the web 80 between the legs 82,84. Maintenance under soldering conditions is included.

When the soldering operation is completed, the fixture is removed as in step 152.

As mentioned above, major advantages derive from the present invention. One of them is that the assembly is easy by means of preparation for inserting the end of the tube 36 into the long hole 86 by forming cam surfaces 96 and 98 surrounding each long hole 86. In addition, there are two advantages by providing flanges 88, 90, 92 and 94 around each long hole 86. One is that the web 80 can be rigidized in the cross-web direction, and the other is formed from the soldered aluminum sheet on both sides in the manner described above, so that the solder coating is the inner surface of the flanges 88,90,92,94. Hold | maintained at 100, and a favorable junction part is formed. That is, the soldered tube-header joint does not require the flow of the solder coating from any other location on the header, nor does it need to be solder coated on the tube 36. In the case where the faces of the flanges 92 and 94 abut each corner of the channel, the core depth is maximized to improve efficiency. In this regard, the header depth can be reduced for other predetermined cores, thereby minimizing the volume of the heat exchanger.

At the same time, the solder coating on the opposite surface of the sheet on which the header 26 is formed forms a solder coating on the inner surface of each of the sections 82 and 84 to form a solder-sealed joint along the respective tanks 10 and 12 and the sections. do. The braze coating below the web 80 on the same side of the original sheet also forms a solder-sealed joint at each end of the header 26 or 28 to the tanks 10, 12.

Accordingly, the present invention not only provides an improved method of manufacturing a heat exchanger that can be used as a charge air cooler, but also provides an improved heat exchanger suitable for use in an inappropriate environment faced by a charge air cooler employed in a vehicle. .

Claims (12)

(a) a fin and tube assembly with solder coating is installed at the interface between the parallel tubes and the pins interposed therebetween, (b) metal channels with solder coating on both sides, and (c) The header plate is formed by forming a series of long holes in the web of the channel, spaced apart from each other in the same shape as the cross section of the tube, and having flanges protruding from the web toward the corners of the channel. d) insert a tube into each slot to assemble the header with the pin assembly located in the flange, (e) assemble the metal tank with the header opposite the pin and tube assembly, and (f) the assembly obtained in step (e) And soldering the fins to the tube, soldering the tube to the flange, and maintaining the header in soldering conditions sufficient to solder the tank. The method of claim 1, wherein the header, tube and tank are made of aluminum. The method of claim 1, wherein step (c) comprises first forming a hole having a smaller size than a cross section of the tube at a predetermined interval, and then driving a punch having a cross section similar to the cross section of the tube through the long hole. Method for producing a heat exchanger, characterized in that for forming a flange connected thereto. 4. The method of claim 3, wherein the tube is a flat tube, the long hole extends between the respective parts, and the flange contacts the each part at an end of the long hole. 5. The cam surface as claimed in claim 4, wherein the actuating of the punch comprises at least partially rounded cam surfaces around each of the long holes opposite the flange to form a pilot surface for mating the tubes by cams in the respective long holes during the step (d). Method for producing a heat exchanger, characterized in that to form a. (a) install a fin and tube assembly consisting of parallel tubes at predetermined intervals and pins interposed therebetween; (b) a channel having angular portions spaced apart from the web; and (c) a tube in the web of the channel. To form a series of long holes spaced apart along the gap of the tube in the same shape as the cross section of the flange, the flanges in the direction of the channel from the web to the periphery, and also to form a pilot face for mating the tube by the cam in the long hole. Forming a header plate by forming a cam surface at least partially rounded around each long hole opposite the flange, and (d) the header plate formed in step (c) is brought into contact with the pin and tube assembly and is moved toward each other relative to each other. By inserting a tube into each slot with or without guidance by first contacting the tube with the round cam surface, and (e) The fixed and, (f) method of manufacturing a heat exchanger, characterized in that comprising the step of bonding the tube and the tank channel. 7. The method of claim 6, wherein step (f) is performed by soldering. Each of which has a heat exchange fluid port and an opening for receiving the header plate, each of which is tapered to have a smaller cross section from the connected port, and is spaced apart from each other to face the first and second tanks facing each other, and a pair of header plays for each tank, respectively. One by one, each formed by an elongate channel having flat central webs formed with portions spaced parallel to the sides, each portion of each header plate correspondingly sealingly joined to both sides of the header plate receiving opening of the combined tank; The web of each header plate includes a plurality of holes having a predetermined interval extending between the respective parts, each hole having a flange around the web side on the same side as the respective parts, and the flange portion at the end of the hole is connected to the connected parts. Approximately in contact with each long hole to guide the tube into the long hole on the web side opposite the flange. A plurality of parallel gaps of predetermined intervals having a pair of header plates at least partially surrounded by a round pilot surface and ends extending between the tank and mating with the long holes at opposite ends of the pair of header plates; A charge air cooler for an internal combustion engine, comprising: a flat tube and an S-shaped pin interposed between the adjacent tube and bonded to the tube. 9. The header plate of claim 8, wherein both sides of the header plate are aluminum coated and solder coated, and a flange inside each of the holes is formed on one side of the header plate and has a solder coating on the side thereof. The header is soldered to the header by a solder coating from one side located inside the flange, the opposite side of each of the sections having a solder coating from the other side of the header plate, the tank being made of aluminum and the solder coating on the other side of the header plate. Charge air cooler, characterized in that soldered to the header plate by. Each of which has a heat exchange fluid port and an opening for receiving a header plate, each of which has an elongated first and second tank spaced apart from each other and a pair of header plays, one for each tank, each having a spaced portion parallel to the side surface thereof. Respectively formed by elongated channels with flat central webs, each part of each header plate correspondingly sealingly joined to both sides of the header plate receiving opening of the combined tank, the webs of each header plate extending approximately between the respective parts; A plurality of long holes of predetermined intervals, each side having a flange at the same side as the respective parts, the flange having a circumference, the flange portion at the end of the long hole being substantially in contact with the connected corner, and each long hole on the web side opposite the flange A pair of headers at least partially surrounded by a round pilot face for guiding the tube into the hole A plurality of parallel flat tubes at predetermined intervals extending between the plate and the tank, the ends of which are mated with the long holes at opposite ends of the pair of header plates, interposed between the tubes and bonded to the tubes Heat exchanger, characterized in that consisting of a fin. 11. The heat exchanger of claim 10, wherein the headers, tanks, tubes and fins are formed of metal and soldered together. 12. The heat exchanger of claim 11, wherein the metal is aluminum and the header plate is solder coated on both sides thereof.