Overmolding insert for heat exchanger, process for manufacturing a heat exchanger, and heat exchanger produced thereby
First Claim
1. An overmolding insert, comprising:
- a base having at least one first opening in a first surface, each said first opening being in communication with a corresponding second opening in a second surface opposite said first surface, at least one hollow projection extending from said first surface of said base, said hollow projection having a first opening in communication with the first opening of said first surface and a second opening located at a terminal portion of said hollow projection, said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space, wherein said terminal portion of said hollow projection extends beyond said partially closed space, and wherein said second surface is only bonded to said end walls and said side walls.
1 Assignment
0 Petitions
Accused Products
Abstract
An overmolding insert includes a base having at least one opening in a first surface, the opening communicating with a second surface opposite the first surface, at least one hollow projection extending from the first surface, the hollow projection having a first opening communicating with the opening of the first surface and a second opening located at a terminal portion of the hollow projection, the insert further having two opposed side walls, each side wall being joined to the first surface, two opposed end walls being joined to an opposite end of the first surface and extending from one side wall to the other side wall. The side walls, the end walls, and the first surface define a partially closed space, with the terminal portion of the hollow projection extending beyond the partially closed space.
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Citations
40 Claims
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1. An overmolding insert, comprising:
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a base having at least one first opening in a first surface, each said first opening being in communication with a corresponding second opening in a second surface opposite said first surface, at least one hollow projection extending from said first surface of said base, said hollow projection having a first opening in communication with the first opening of said first surface and a second opening located at a terminal portion of said hollow projection, said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space, wherein said terminal portion of said hollow projection extends beyond said partially closed space, and wherein said second surface is only bonded to said end walls and said side walls. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
wherein said side walls and said end walls each have a terminal segment located opposite to where said side walls and said end walls join to said first surface, and wherein said terminal segment is raised to a higher temperature upon being contacted with molten polymer than a remainder of said insert. -
12. The overmolding insert of claim 11, wherein a thickness of said base is the same thickness as a thickness of said terminal segment of said side walls and said end walls.
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13. A heat exchanger, comprising
a plurality of hollow conduits each having a first end and a second end; -
a first manifold having an internal space, said first manifold connected to said first end of each conduit such that said hollow conduit is in communication with said internal space;
a second manifold connected to said second end of each conduit;
wherein at least one of said first and second manifolds is joined around said conduit ends and at least one overmolding insert such that a hollow conduit is fitted over a hollow projection, wherein said overmolding insert comprises a base having at least one first opening in a first surface, each said first opening being in communication with a corresponding second opening in a second surface opposite said first surface, at least one hollow projection extending from said first surface of said base, said hollow projection having a first opening in communication with the first opening of said first surface and a second opening located at a terminal portion of said hollow projection, said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space, wherein said terminal portion of said hollow projection extends beyond said partially closed space. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
a base having at least one opening in a first surface, said opening being in communication with a second surface opposite said first surface, said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space, wherein said overmolding insert and said subplenum adapter insert define an enclosed chamber between them, wherein said enclosed chamber communicates with said internal space of said manifold through a plurality of first openings, and said enclosed chamber communicates with said hollow conduits through a plurality of second openings, and wherein said plurality of first openings have a smaller total area than said plurality of second openings.
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28. The heat exchanger of claim 26, further comprising at least one additional row of coplanar hollow conduits parallel to and spaced from said first row of hollow conduits.
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29. The heat exchanger of claim 13, wherein said manifolds and said hollow conduits comprise a polymeric material.
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30. The heat exchanger of claim 29, wherein said polymeric material is thermoplastic.
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31. The heat exchanger of claim 13, wherein a plurality of said hollow conduits are joined together through a web in a coplanar orientation.
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32. The heat exchanger of claim 31, wherein a portion of said web located at an end has been removed to create a notch in which a mass of manifold material having a thickness which is at least equal to a thickness of a manifold wall is located after an overmolding process to form a manifold has been completed.
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33. The heat exchanger of claim 31, wherein a portion of said web located at an end has been removed to create a hole in which a mass of manifold material is located after an overmolding process to form a manifold has been completed.
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34. An overmolding insert, consisting of:
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a base having a plurality of first openings in a first surface, said first openings being in communication with a plurality of second openings in a second surface opposite said first surface, a plurality of hollow projections extending from said first surface of said base, each said hollow projection having a first opening in communication with said first opening of said first surface and a second opening located at a terminal portion of said hollow projection, said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space, wherein said terminal portions of said hollow projections extend beyond said partially closed space. - View Dependent Claims (35, 36, 37, 38, 39, 40)
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Specification