U.S. patent application number 11/414706 was filed with the patent office on 2007-11-01 for heat exchanger assemblies having hybrid tanks.
This patent application is currently assigned to Valeo, Inc.. Invention is credited to Philip J. Davis, Sameer Desai.
Application Number | 20070251683 11/414706 |
Document ID | / |
Family ID | 38963142 |
Filed Date | 2007-11-01 |
United States Patent
Application |
20070251683 |
Kind Code |
A1 |
Desai; Sameer ; et
al. |
November 1, 2007 |
Heat exchanger assemblies having hybrid tanks
Abstract
Heat exchanger assemblies, and, in particular, heat exchanger
assemblies that function in high pressure and/or temperature
environmental conditions, are described. An essential feature of
the heat exchanger assembly is the presence of an hybrid tank
comprising both plastic or plastic like materials and metal or
metal alloy materials, that provides for good structural integrity
and operation of the assembly under high pressure and/or
temperature conditions.
Inventors: |
Desai; Sameer; (Lake Orion,
MI) ; Davis; Philip J.; (Lapeer, MI) |
Correspondence
Address: |
Valeo, Inc.;Intellectual Property Department
4100 North Atlantic Boulevard
Auburn Hills
MI
48326
US
|
Assignee: |
Valeo, Inc.
Auburn Hills
MI
|
Family ID: |
38963142 |
Appl. No.: |
11/414706 |
Filed: |
April 28, 2006 |
Current U.S.
Class: |
165/173 ;
165/133; 165/905 |
Current CPC
Class: |
F28F 19/04 20130101;
F28F 21/084 20130101; F28D 2021/0082 20130101; F28F 21/067
20130101; F28F 21/089 20130101; Y10T 29/4935 20150115 |
Class at
Publication: |
165/173 ;
165/133; 165/905 |
International
Class: |
F28F 9/02 20060101
F28F009/02 |
Claims
1. A heat exchanger for an automotive vehicle comprising: a first
end tank; a second end tank opposite the first end tank; a
plurality of essentially parallel tubes in fluid communication with
the first and second end tanks; at least one fin contacting at
least two of the plurality of tubes, with the parallel tubes and
the fins being generally co-planar relative to each other; wherein
at least the first end tank or the second end tank is an hybrid
tank.
2. A heat exchanger as in claim 1, wherein the hybrid tank
comprises a metal or metal alloy type material and a plastic or
plastic like material.
3. A heat exchanger as in claim 2 wherein the hybrid tank comprises
at least three different materials.
4. A heat exchanger, as in claim 3, wherein one of the materials is
a coating material.
5. A heat exchanger as in claim 4, wherein the coating material
comprises a thermally dissipative or barrier type coating.
6. A heat exchanger as in claim 4, wherein the coating material
comprises a chemically resistant or barrier type coating.
7. A heat exchanger, as in claim 4, wherein the coating material
comprises both a chemically resistant and a thermal barrier or
dissipative type coating.
8. A heat exchanger, as in claim 4, wherein the heat exchanger is
adapted to function in high internal temperature and/or pressure
environments.
9. A heat exchanger, as in claim 4, wherein the heat exchanger is
selected from the group consisting of charge air cooler (CAC),
exhaust gas recycling cooler (EGR), and intercoolers.
10. A heat exchanger, as in claim 9, wherein the coating material
is selected from the group consisting of thermally dissipative,
thermal barrier, chemically resistance and chemical barrier type
coating.
11. A heat exchanger as in claim 10, wherein the coating material
is applied to the interior surface of the wall of the hybrid
tank.
12. A heat exchanger, as in claim 2, wherein both the first end
tank and the second end tank are hybrid tanks.
13. A heat exchanger, as in claim 2, wherein the hybrid tank
comprises a metal shell.
14. A heat exchanger, as in claim 13, wherein the hybrid tank
comprises at least one plastic adjunct.
15. A heat exchanger, as in claim 13, wherein the hybrid tank
comprises a metal shell, and wherein at least one metal part of the
metal shell and at least one plastic adjunct form a plastic-metal
section.
16. A heat exchanger, as in claim 15, wherein a plurality of metal
parts of the metal shell form plastic-metal sections.
17. A heat exchanger, as in claim 16, wherein the metal shell is
made of sheet metal.
18. A heat exchanger, as in claim 16, wherein the plastic-metal
sections are sealed by bonding, adhesives or forming of an
interfacial layer at the interfaces of the plastic adjuncts and the
metal shell.
19. A method of manufacturing a hybrid tank for an automotive
vehicle heat exchanger comprising: providing a metal shell
comprising one or more metal sections for the hybrid tank;
combining one or more plastic sections with the one or more metal
sections; forming plastic-metal sections between the metal shell
and plastic adjuncts; whereby the hybrid tank thereby produced is
leak-tight and able to withstand high temperature and/or pressure
conditions.
20. A method, as in claim 19, wherein the metal shell comprises
sheet metal.
21. A method, as in claim 20, wherein the plastic-metal sections
are formed by providing for perforations or spaces in-between metal
sections of the metal shell, and flowing plastic or plastic like
material by or into the perforations or spaces to form
plastic-metal sections.
22. A method, as in claim 20, wherein the metal shell comprises
metal to metal mechanical interface points and plastic-metal
sections.
23. A method, as in claim 20, wherein the metal portions of the
metal shell are arranged such that they increase strength of the
hybrid shell is specific areas.
24. A method, as in claim 21, wherein the perforations or spaces
are aligned such that the majority of all of the plastic-metal
sections can be formed in a one step operation.
25. A method, as in claim 19, further comprising the step of
coating at least part of the interior surface of hybrid tank after
the plastic-metal sections are formed.
26. A method, as in claim 25, wherein the coating is selected from
the group consisting of thermally dissipative, thermal barrier,
chemically resistance and chemical barrier type coating.
27. A method for forming an heat exchanger assembly by assembling
the hybrid tank of claim 19 with other elements of an automotive
heat exchanger, to form a heat exchanger assembly.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to heat exchanger assemblies,
and, in particular, heat exchanger assemblies that function in high
pressure and/or temperature environmental conditions.
BACKGROUND OF THE INVENTION
[0002] Current tank or tanks for heat exchangers, especially high
pressure and/or temperature heat exchangers such as charge air
coolers, use materials such as cast aluminum for tanks subjected to
high temperatures and/or pressure conditions.
[0003] JP2003314287 (A) identifies use of cast Aluminum tanks which
are welded to the heat exchanger core. EP1524105 (A2, A3)
identifies bonding of two material to form a structural part.
[0004] The use of cast aluminum tanks, however, means that such
heat exchangers are required to have certain limitations, such as
design limitations/need for complex features to provide for
dimensional stability and/or part integration; additional
manufacturing steps or operations to accomplish outcomes not
possible using a casting aluminum process alone; higher costs due
to these additional or secondary operations, welding necessary for
tanks to the heat exchanger for assembly, high weight, and, in
certain cases, inadequate corrosion resistance.
[0005] Heat exchangers have also used plastic tanks or manifolds
(`tanks`) to meet product requirements. For example, plastic charge
air cooler tanks or tanks are used where the application
temperature and pressure allows one to design them to meet the
product requirements. Once specifications for temperature and
pressure increase to a point where plastic tanks have limitations,
cast aluminum tanks are often considered and used.
[0006] For cast aluminum tanks there is some machining required
which, as described above, leads to higher overall costs. Also,
cast aluminum tanks can be designed with heavy wall sections and
its characteristics mean that the types of part designs that can be
implemented do not achieve the goal of reducing overall costs
enough to make them as commercially desirable as wanted.
[0007] Using of cast aluminum tanks for heat exchanger requires
welding of tanks in most cases to the heat exchanger and this
either requires robots and more time and quality sensitive
manufacturing step in the system. With plastic tank this step is
reduced by having gasket and standard crimp process.
[0008] As shown in FIG. 1a tank is heat exchanger designed with
cast aluminum Tank FIG. 1b shows the cast aluminum tank.
SUMMARY OF THE INVENTION
[0009] In aspects of the present invention, a heat exchanger
capable of functioning in high temperature and/or pressure
environments, with a lower profile cost for the same or better
performance than aluminum cast tanks, is provided. In addition, the
strength and performance characteristics of lower temperature
and/or lower pressure environment plastic tank systems is enhanced
with the hybrid tanks of the present invention. Examples of high
temperature environments are those where tanks for applications
where temperature is higher than 220.degree. C., and, particularly
where temperatures and pressure are both at a high level. For
example, at high temperatures, internal pressure is higher, for
example greater than 30 psi.
[0010] Aspects of the present invention, therefore, provide for
extended application ranges for hybrid tanks than either cast
aluminum or plastic tanks alone, particularly for use in an
automotive vehicle, with lower weight with good performance versus
cast aluminum only tanks, and potentially lower cost (for example,
through less time to manufacture and elimination of machining,
welding and allowing integration of features not possible through
metal casting methods) versus prior heat exchanger art tanks.
Otherwise stated, aspects of the present invention allow for a
larger degree of design freedom (more integration of features which
can not be feasible through metal casting processes).
[0011] Various aspects of the present invention allow for plastic
or plastic like parts and features of a heat exchanger to exist in
conjunction with parts and features made of other materials. The
plastic or plastic like parts can be formed or produced, for
example, with processes such as, but not limited to, injection
molded, blow molded or compression molded or plastic cast
components. Produced parts, for example, do not require secondary
operation at all or require minimum secondary operations after a
main or principle manufacturing step in order to produce the end
product.
[0012] In specific aspects of the present invention, materials such
as plastic or plastic like materials and metal or metal alloy
materials are used together to form a `hybrid tank`. For example, a
tank is made conforming to a plastic and metal hybrid design,
wherein routine machining, such as in the prior art for metal
tanks, is eliminated or minimized.
[0013] Various aspects of the present invention, therefore, extend
the application range possible for heat exchanger, and, especially
for high temperature and/or pressure environment heat exchangers
such as CACs (Charged Air Coolers) or intercoolers. By providing
for combined properties of two or more materials, strengthened
tanks at lower weight and cost than cast aluminum tanks or tanks,
gain advantages, especially in terms of design freedom. Use of
plastic or plastic like materials, in addition to metal or metal
alloy materials in tanks, as stated above, allows integration of
features which are not possible through metal casting.
[0014] Tubes are present in automotive heat exchangers and heat
exchanger assemblies. For example, in a heat exchanger with a
plurality of tubes, the plurality of tubes can have at least one
tube with a plurality of sub-passageways extending along a length
of the at least one tube and wherein each of the sub-passageways of
the at least one tube has a cross-sectional area perpendicular to
the length of the at least one tube that is between about 0.02
mm.sup.2 and about 1.00 mm.sup.2.
[0015] Tanks, such as those used in the heat exchanger assemblies
of the present invention, may be used in various applications where
automotive fluids are handled. Particularly in high pressure and/or
temperature environments, where plastic only tanks can not meet, or
with great difficulty, meet specifications, such as EGR coolers, or
charged air intake tank, or intake manifolds hybrid tanks not only
have the structural features necessary to meet such specifications,
but also are light and formable enough to be used in a variety
tight space packaging, as well as high temperature/pressure
environments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1a is an example of prior art heat exchanger with cast
aluminum tank.
[0017] FIG. 1b is a cast aluminum tank as found in current heat
exchangers.
[0018] FIG. 1c is an interior view of a cast aluminum tank as in
current art.
[0019] FIG. 1d is a cross section of an all plastic tank which has
a metal insert in the fluid connection area only.
[0020] FIG. 2 is a schematic side view of an hybrid tank, in
accordance with an aspect of the present invention.
[0021] FIG. 3 is a schematic interior view of an hybrid tank of
FIG. 2, in accordance with an aspect of the present invention.
[0022] FIG. 4 is a schematic view of metal shell for an hybrid
tank, in accordance with an aspect of the present invention.
[0023] FIG. 5 is a schematic cross sectional view of metal shell
for an hybrid tank, in accordance with an aspect of the present
invention.
[0024] FIG. 6 is a rotated sectional view of metal shell for an
hybrid tank, in accordance with an aspect of the present
invention.
[0025] FIG. 7 is a schematic cross sectional views of hybrid tank,
in accordance with an aspect of the present invention.
[0026] FIG. 8 is a schematic cross sectional view of plastic-metal
sections or `joints` of a hybrid tank, in accordance of an aspect
of the present invention.
[0027] FIG. 9 is a schematic cross sectional view of additional
plastic-metal sections or `joints` of an hybrid tank, in accordance
with an aspect of the present invention.
[0028] FIG. 10 is a schematic cross sectional view of an hybrid
tank, further comprising a coating on the tank, in accordance with
an aspect of the present invention.
[0029] FIG. 11 is an interior schematic view of hybrid tank,
comprising additional structural components to improve tank
performance, in accordance with an aspect of the present
invention.
[0030] FIG. 12 is a schematic cross sectional view of plastic-metal
sections, bonded using adhesive, in accordance with an aspect of
the present invention.
DESCRIPTION OF VARIOUS EMBODIMENTS OF THE PRESENT INVENTION
[0031] Heat exchanger assemblies, and, especially, heat exchanger
assemblies operating in high temperature and/or pressure
environments, allow increased temperature and pressures range of
application of lower weight and cost tanks. Hybrid tanks, as in the
various aspects of the present invention, are therefore useful to
replace cast aluminum, or even other metal tanks, such as stamped
and brazed aluminum tanks.
[0032] The metal part or parts of the hybrid tank are located in
the hybrid tank in at least one, and, more specifically, in a
plurality of areas. The metal part or parts, together referred to
as the `metal shell`, is provided in one strategic area or, in a
plurality of areas, or in all of areas necessary to provide the
correct rigidity or stiffness for its own particular heat exchanger
application, in accordance with the applicable specification. For
example, for heat exchanger assemblies comprising a charge air
cooler, the metal shell provides stiffness which allows areas of
the hybrid tank to resist high pressures at specified temperatures.
The plastic part or parts of the hybrid tank (plastic adjuncts) are
formed or otherwise assembled together with the metal shell such
that they have essentially leak proof seals between metal and
plastic areas of the hybrid tank, thereby rendering the tank
so-called `leak tight`.
[0033] The metal shell of the heat exchanger tank may comprise
metal or metal alloy derived from a sheet of metal or metal allow
(sheet metal).The combination of sheet metal and plastic takes
advantage of the properties of sheet metal to take large loads
(sheet metal form (which is in 0.3.gtoreq.t .ltoreq.4 mm
thickness), versus, for example, the typical cast aluminum tanks of
width or thickness which are often greater than or equal to
3.gtoreq.t .ltoreq.6 mm, wherein t is the average thickness. The
properties of the plastic, particularly, for example, lower
densities compared to aluminum, allow for a lighter overall tank
and subsequently heat exchanger and assembly weight, and ease of
manufacturing of complex features on or associated with the hybrid
tank.
[0034] The area of hybrid tanks at the junction of contact of metal
and plastic parts is called, herein, `plastic-metal sections`.
Together, the plastic-metal sections form part of the overall tank
and the tank comprises the metal shell and plastic adjuncts.
[0035] These plastic-metal sections, also referred to on occasion
as mechanical joints or mechanical interface joints can be
envisioned in many ways. Simplistic joint is shown where plastic
flows through strategically placed perforations in the metal and
thus creating a mechanical joint. The number and type of mechanical
joint varied per location through out the tank and also from one
tank design to other tank designs. The purpose of the mechanical
joint is to allow some deformations and loads seen during the duty
of the part. In various aspects, the plastic adjuncts and the metal
sections can be bonded, glued, or otherwise held together, either
by a general bonding process, by adhesives, or by forming an
interfacial layer of a product to help form a seal. Plastic-metal
sections can be bonded together.
[0036] Aspects of the present invention also provide for the use of
a coating, such as thermal barrier, or thermally dissipative,
coatings, that is applied to various areas of the hybrid tank.
Aspects of the present invention having such coatings, means that
the application range of current systems can be further expanded to
cover higher heat and pressures, through improve the thermal and
chemical resistance of the product. Examples of liquid coatings are
numerous and are found in standard formulations and used in the art
on a regular basis. One such example includes coatings such as
thermal barrier type coating like IC-105 from Techline Coating.
Preferred are coating that practically eliminate or highly reduce
oxidation by isolating the majority of the base material from
higher temperatures.
[0037] Other examples of coatings useful for applications of the
present invention including thermally dissipative type coating,
with or without supplemental coating substances can provide other
characteristics in addition to heat management and chemical
resistance. For higher temperature applications, thermally
dissipative coatings can include, for example, a thermally cured
heat emitting coatings, that can be combined with other materials,
such as pigment, to provide corrosion protection as well as being
applied as a thin film. Various coatings, and particularly those
applied as thin films tend not to reduce surface area by filling in
surface porosity. For example, a coating is applied on the interior
or exterior or both walls of the hybrid tank. Also, essentially all
or one can envision only some portion of the tank, may use such a
coating. Preferred coating, in various aspects, is done on the
internal or `interior` surface of the wall of the tank.
[0038] FIG. 1a, (100) is a typical heat exchanger, having tanks
(101) and (102) are provided to remove and accept fluid from
vehicle systems respectively. Tank (101) which is outlet tank, is
typically made entirely out of plastic, particularly since outlet
temperatures, usually and in some cases, also pressures, are lower.
Tank (102) is inlet for fluid entering in the heat exchanger (100).
For cooling heat exchangers the temperature and pressure of the
fluid entering in the inlet tank 1(02) is high. Tank (102) is made
of metal or materials which can withstand higher temperature or
pressure. FIG. 1a has a cast aluminum tank (110). Heat exchanger
(100) shows that tanks are connected by header (104) and (1 10).
The main heat exchanger portion of the heat exchanger is called the
core (103). Core (103) is made up of tubes and fins (not shown).
The tubes of the core allow fluid to exchange heat with out side
environment in combination with fins. Also shown are mounting
features (106,107,108 and 109) (features which allow one part to
attach to another part so as to retain portions of the heat
exchanger to another with ascertain proximity) typical to such heat
exchangers.
[0039] FIG. 1b, (160) shows a cast aluminum tank or aluminum sheet
metal brazed or welded tank (not shown) also exits. Interface
features such as outlet connector (161), foot area (162) and
mounting features (163) and (164) are shown. Cast aluminum tank
requires additional machining to finish desired for interface
features especially tank foot and fluid connectors.
[0040] FIG. 1C, (180) is an inside view of the tank (160). Again
shown are the features (181,182 and 183).
[0041] In FIG. 1D, is the cross section view of the tank (190) made
entirely out of plastic (191) where fluid connection section (193)
has metal sleeve (192) inside. Sleeve (192) helps prevent creep in
plastic and maintain its shape during it life cycle.
[0042] FIG. 2 illustrate tank (200) is made with more than two
materials. Tank (200) typically has multiple interfaces such as
connector for the fluid handling (201), foot interface (202)
connected to the core portion of the heat exchanger described in
FIG. 1a and mounting features (203) and (204).
[0043] FIG. 3 illustrates tank (300) with interior view of tank
(200) of FIG. 2. Connector (301), foot (305), mounting feature
(302) is shown. Mechanical interface points (303, 304 and 306). The
mechanical interface points (plastic-metal sections) are joints
between sheet metal and plastic.
[0044] In FIG. 4, metal shell (400) is shown with details
(401,402,403 and 404). Details (401, 402 and 403) are perforations
provided in the metal sections for allowing plastic to flow and
form a mechanical interface joint. Plastic-metal section detail
(404) shows the mechanical interface joint between two sections of
metal; where two separate metal sections are brought together.
[0045] FIG. 5 shows a cross section (500) as shown in FIG. 4 at
Section B-B item (405) showing further details of some of the
mechanical interface joint sections. Cross section (500)
illustrates two pieces are joined at location (506), sheet metal
wall is shown (501). Perforations (502, 503, 504 and 505) are
formed in a manner to allow plastic to flow and create a mechanical
interface joint (plastic-metal section). Perforations in wall
section (501) may be added (not shown) as needed by the
product.
[0046] The metal shell is comprised of a part or parts found in
specific areas where strength is required to be enhanced, for
example, to meet product specifications. Such areas can be, for
example, areas of increased load, high pressure concentration in
the tank, areas exposed to increased temperatures, etc.
[0047] In FIG. 6, tank metal section (400) is shown in respective
sections (600 and 620). Section (600) shows features of the metal
sections. Spaces or perforations (602, 604) are shown for section
(600). When there is more than one perforation or space, the
perforations or spaces can be aligned or unaligned. Similarly,
perforations (625, 623) are shown for section (620). Sections (600)
and (620) form shell (400), these perforations get aligned and
create a location for plastic to form a plastic-metal section.
Section (600) areas (606, 608, 610, 611) and section (620) has
areas (626, 627, 628, 629); when sections (600) and (620) are
joined to form a shell (400), these areas create a plastic-metal
section (joint) shown as item (404) or (506). The sections (600 and
620) have walls (609) and (624) respectively which can again be
perforated as desired to create locations for making the joint with
plastic.
[0048] FIG. 7, is a cross section (700) of a finished tank (Section
A-A) shown in FIG. 5. Cross section (700) shows plastic section
(701) and metal section (702). Also shown are the interface
features such as tank foot (703, 800) and fluid connecting port
(708). This cross section shows plastic-metal section between
plastic and metal sections at (707, 706, 704 and 705). Also shown
is the area where two metal sections and plastic sections come
together (709).
[0049] FIG. 8, is an enlarged view (800) of the bottom section of
(700), as one of the configuration which can be envisioned for
joining metal and plastic. (801) is the foot area (901), plastic
section (803) is and metal section (804) is shown. (802) is the
plastic-metal section.
[0050] FIG. 9 illustrates an enlarged view (900) of the top section
of cross section (700). The plastic section (901) and similarly,
metal section (902 are shown. Fluid interface connector (905) exist
as a feature. Items (905) and (906) show one of the approaches to
joining plastic to metal mechanically.
[0051] FIG. 10 shows cross section (1000) with another variation
where the tank wall is coated with a protective coating on its
interior surface, which can be a corrosion resistant or thermally
resistive or dissipative coating or coatings are generally used.
Shown here is coating (1003) applied preferably to inside or
interior surface as shown. Plastic section (1001) and metal
section, (1002) are protected by coating (1003) from fluid or
environment inside the tank.
[0052] FIG. 11 shows interior view of tank (1200), having bridges
or tie rods (1207) and (1208) between walls (1206) and (1205)
respectively. Shown in this view are features (1203) for mounting,
fluid connection features (1201), (1202) foot area, and location of
mechanical joint between metal and plastic (1204), is provided.
[0053] FIG. 12 shows the tank (1300) in a cross sectional view.
Plastic section (1301) is bonded to metal section (1303) with a
bonding material (1302). Plastic and metal sections can, of course,
can be envisioned to be in opposite orientation to what is shown
here. In cross section, plastic material section (1301) is
manufactured and bonding material (1302) is applied to either a
plastic section (1301) or a metal section (1303) and then plastic
and metal section with one of them carrying bonding material are
brought together to form the plastic-metal section. Also shown is
fluid connection area (1304) where interior surface (1305) is
shown, without optional metal sleeve.
[0054] It can also be envisioned that metal portions and plastic
portions are separately manufactured and joined in a secondary
operation v/s in the die or tool to form a shaped part. For
example, ultrasonic or vibration welding processes, may be
used.
[0055] The metal section (metal shell) can be manufactured in one
part, in its entirety, through a deep draw process, for example, or
can be in more than one piece.
[0056] Various aspects of the present invention relate to a method
of manufacturing heat exchanger assemblies comprising a hybrid
tank. In one such method, an hybrid tank is formed by assembly a
metal shell or shells and plastic material in such a way that a
fluid-tight hybrid tank comprising plastic-metal sections is
made.
[0057] At least one metal portion or part is placed in the mold or
die to provide the metal section, plastic material is provided in
desired areas not adequately or appropriately provided by the metal
section.
[0058] An hybrid tank is, preferably, assembled as part of a heat
exchanger assembly, thereby providing for an heat exchanger
comprising a hybrid tank, and such hybrid tank as part of the
assembly. The metal shell can also be located, piece by piece, into
a mold at various time intervals. For example, multiple positioning
of metal sections and multiple plastic injections to form plastic
sections adjuncts at various areas and at various time intervals,
can be done to achieve desired product functionality in the
finished hybrid tank.
[0059] In one aspect of the present invention, the metal part or
parts are placed in a mold or die to provide, or form, a metal
shell. Plastic adjuncts or sections are provided in the strategic
areas to produce a hybrid tank of desired strength, size and weight
(note that metal portion can be one or more of them). Vice versa,
the plastic adjuncts can be provided to various areas of a mold or
die, and metal parts can be added at strategic areas to produce an
hybrid tank of desired size, strength and weight.
[0060] In various aspects, for example, the plastic section or
adjunct is molded separately and also metal sections are formed
separately. The plastic and metal sections are arranged in a mold
or die or a fixture and are joined by injecting plastic again to
join metal and plastic section using a same material or different
material.
[0061] Additional structure features may also be added to the
hybrid tank to improve tank, and, therefore, overall heat exchanger
assembly performance. For example, tie rods, bars, structural
supports, or other bridging means to support at least two areas of
the tank, as provided in various aspects of the present invention.
These additional structural features provide additional structural
strength where desired.
[0062] In various aspects of the present invention, structural
analysis of embodiments aids to define the thickness of metal sheet
or portions and distribution of plastic to metal joints based on
the functional requirements of the part.
[0063] Unless stated otherwise, dimensions and geometries of the
various structures depicted herein are not intended to be
restrictive of the invention, and other dimensions or geometries
are possible. Plural structural components can be provided by a
single integrated structure. Alternatively, a single integrated
structure might be divided into separate plural components. In
addition, while a feature of the present invention may have been
described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0064] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize
however, that certain modifications would come within the teachings
of this invention. Therefore, the following claims should be
studied to determine the true scope and content of the
invention.
* * * * *