US 11,745,295 B2
Manufacture of heat exchangers via hybrid welding
Stephen Thompson, Quebec (CA); Nuno Demetrio-Soeiro, Quebec (CA); and Nicolas Becker, Porte du Ried (FR)
Assigned to Sogefi Air & Cooling USA, Inc., Rochester Hills, MI (US)
Filed by Sogefi Air & Cooling USA, Inc., Rochester Hills, MI (US)
Filed on Jan. 19, 2022, as Appl. No. 17/579,277.
Claims priority of provisional application 63/166,545, filed on Mar. 26, 2021.
Prior Publication US 2022/0305597 A1, Sep. 29, 2022
Int. Cl. B23P 15/26 (2006.01); F28F 21/06 (2006.01); B29C 65/08 (2006.01); B29C 65/00 (2006.01); B29C 45/14 (2006.01); H01M 10/6556 (2014.01); B29L 31/18 (2006.01)
CPC B23P 15/26 (2013.01) [B29C 45/1418 (2013.01); B29C 65/08 (2013.01); B29C 66/0246 (2013.01); B29C 66/72 (2013.01); B29C 66/742 (2013.01); F28F 21/062 (2013.01); H01M 10/6556 (2015.04); B29L 2031/18 (2013.01); H01M 2220/20 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method for manufacturing a heat exchanger, the method comprising:
laser-texturing a portion of a first surface of a metal substrate to form a plurality of microstructures therein, the plurality of microstructures including a plurality of undercut channels that are spaced apart from each other along a portion thereof;
melt-bonding a plastic housing to the laser-textured portion of the first surface of the metal substrate, such that a molten portion of the plastic housing flows into the plurality of undercut channels defined in the metal substrate, wherein melt-bonding the plastic housing includes ultrasonically welding the plastic housing to the first surface of the metal substrate; and
permitting the molten portion of the plastic housing to harden while within the plurality of undercut channels, thereby joining the plastic housing to the metal substrate, wherein the plastic housing and the metal substrate define a first flow chamber for a thermal fluid, and wherein the plastic housing and the metal substrate provide a leak barrier for the thermal fluid moving through the first flow chamber,
wherein the plastic housing is a first plastic housing, the method further including laser-texturing a portion of a second surface of the metal substrate opposite of the first surface and ultrasonically welding a second plastic housing thereto, wherein the first and second plastic housings are joined to opposing surfaces of the metal substrate, and wherein the second plastic housing and the metal substrate define a second flow chamber for the thermal fluid.