Abstract: The invention relates to a method for laser welding at least two components made of plastic, particularly a pipe and a carrier plate, wherein the first component at least in certain regions has a relatively high permeability for the laser beam used during laser welding. The second component at least in certain regions has a relatively low permeability for the laser beam used during laser welding. A compact design of the components can be achieved if the laser beam reaches the respective weld location by means of refraction and/or reflection during laser welding.

Abstract: A plastic intercooler assembly includes a plurality of plastic tubes that extend between plastic end plates. The plastic tubes are secured to the end plates to provide the desired seal between the end plates and the ends of the tubes. The plastic tubes are attached utilizing plastic welding methods that reduce assembly time and cost.

Abstract: An intercooler assembly includes a housing that defines an internal space containing a plurality of tubes. A joint between a tube and a tube plate is created by a laser welding process. A form presses the walls of the tube outwardly to form the flange. The downward force of the form not only creates the desired flange, but also exerts a pressure that holds the flange against the tube plate. The form provides for the transmission of laser energy to that the creation of the flange can be performed concurrently with the welding process.

Abstract: An example plastic intake manifold is assembled with an inner shell received within an outer shell. The method of assembling the outer shell to the inner shell comprises a localized thickness that defines a desired laser weld joint along which laser energy is utilized to form the desired joint between the outer shell and the inner shell. The method also provides for completing a desired weld around an interfering protrusion on an outer surface of the outer shell.

Abstract: An intercooler comprises a plurality of plastic cooling tubes extending between a first end plate and a second end plate and a baffle arranged in the intercooler and extending at least partially between the first end plate and the second end plate. The baffle comprises a plurality of first openings for receiving a respective plastic cooling tube, the baffle further comprising a plurality of second openings arranged between the first openings. The second openings permit air to flow through the intercooler whilst creating turbulence in the air flow which increase the thermal transfer between the air and the tubes increasing the efficiency of the intercooler.

Abstract: A plastic intercooler assembly includes a plurality of plastic tubes that extend between plastic end plates. The plastic tubes are secured to the end plates to provide the desired seal between the end plates and the ends of the tubes. The plastic tubes are attached utilizing plastic welding methods that reduce assembly time and cost.