Why Ultra-Seal® for Intercoolers?

Ultra-Seal® is a patented, high temperature, silicone-polymer grommet system designed to seal the core tubes to the manifold without welds.  The Ultra-Seal® design also eliminates the traditional header welds by using one-piece, unitized manifolds. 

The two main failure modes for traditional intercoolers are cracks at the tube-to-header joint, and cracks in the header-to-manifold weld.  The grommets virtually eliminate the high stresses at the tube-to-header joint.  No stress, no cracks!  The unitized manifolds eliminate the welds at the header-to-manifold joint.  No welds, no cracks! 

Ultra-Seal® cores are designed for performance.  Our "window" fin allows for superb cooling performance, reduced pressure drop, low weight and resistance to clogging.     

Ultra-Seal® manifolds are one-piece, investment cast 356 Alloy aluminum construction.

Ultra-Seal® grommets are extremely stable, and are rated for temperatures from -40F to 600F.

The Ultra-Seal® design is tested and qualified to meet the cooling performance and durability requirements of the most severe OEM Class-8 truck, military vehicle and fire rescue applications.

Need we say more?

 
Profile view of grommet/tube installation into the manifold.

Note: the grommet lip on the far side of the manifold/header has been expanded by the insertion of the tube, to create inner seal.

Strain Activity Comparison

This graph shows strain level (unit deflection of air-to-air charge air cooler tubes) at the tube-to-header joints of an Ultra-Seal® Intercooler and a typical bar and plate intercooler as a result of starts, stops, and accelerations.  The jagged curve indicates widely varying strains in the fully brazed bar and plate intercooler. The steady (non varying) curve shows the lack of strain response of the grommeted Ultra-Seal® Intercooler during similar events.  This lack of strain response activity indicates a theoretically leak-free life for the Ultra-Seal® Intercooler.