Hybrid spigot and method therefor

Abstract

A hybrid spigot for use with a fluidic system defining an opening includes a metal base and a thermoplastic body. The metal base includes a first bonding surface, a second bonding surface, and an inner surface. The first bonding surface includes a micro-textured region defining a plurality of undercut channels. The thermoplastic body has a proximal end, a distal end, an exterior surface, and an interior surface. The thermoplastic body includes a retaining structure for a coupler and a bonding flange. The bonding flange includes a bonding interface surface that penetrates the plurality of undercut channels of the micro-textured region to join the thermoplastic body to the first bonding surface of the metal base. The interior surface of the thermoplastic body defines a flow chamber disposed about a normal axis.

Description

HYBRID SPIGOT AND METHOD THEREFORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application 63 / 530,824, filed August 4, 2023, the disclosure of which is incorporated by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a hybrid spigot for the manufacture of fluidic systems such as heat exchangers for dissipating heat accumulating in battery cells and in other applications.BACKGROUND

[0003] Heat exchangers, especially those involving fluids such as water, glycol- based liquids, oil, and air, are an indispensable and ubiquitous element of many mechanical, electrical, or hydraulic systems. For example, heat exchangers are commonly used in electrical vehicles to draw heat away from batteries having a high operating voltage. Lithium-ion battery cells are known to generate significant heat during charging and discharging. For this reason, heat exchangers are typically placed in thermal communication with the battery cells to transfer heat to a suitable thermal cooling fluid.

[0004] Heat exchangers and in particular cooling plates are typically formed from stamped components such as panels comprising metals such as steel, stainless steel, and aluminum. These often-heavy components are welded, brazed, or mechanically assembled to form the necessary architecture of the heat exchanger. Mostheat exchangers include a flow chamber for circulating a thermal cooling fluid. Heat(e.g., from a battery module) is absorbed by the cooling plate (e.g., from the battery module) and transferred to the cooling fluid circulating in the flow chamber to cool a desired component (e.g., the battery module). As such, heat exchangers require inlet and outlet ports in the form of spigots, which can be quickly connected to fluid lines, which are in turn connected with a fluid source. Spigots can be difficult to assemble and affix to heat exchangers because of their smaller size and complex shape and can interfere with assembly operations such as welding. For example, spigots may include a retaining structure for quick coupling that interferes with welding processes. As another example, spigots must be aligned with an orifice in order to put the flow chamber in fluidic communication with the fluid source.

[0005] As such, there is a need for an improved spigot that can be manufactured efficiently, is light weight and durable, and, importantly, can easily be assembled with a heat exchanger.SUMMARY

[0006] A hybrid spigot for use with a fluidic system defining an opening is disclosed. The hybrid spigot comprises a metal base and a thermoplastic body. The metal base includes a first bonding surface, a second bonding surface, and an inner surface. The first bonding surface includes a micro-textured region defining a plurality of undercut channels. The thermoplastic body having a proximal end, a distal end, an exterior surface, and an interior surface. The thermoplastic body includes a bonding flange and a retaining structure for a coupler. The bonding flange is at the proximal end of the thermoplastic body and defines a bonding interface surface. A portion of the bonding interface surface penetrates the plurality of undercut channels in the microtextured region. The retaining structure is spaced axially from the distal end of thethermoplastic body. The interior surface of the thermoplastic body defines a flow chamber disposed about a normal axis. When the second bonding surface of the metal base is attached to the fluidic system, the flow chamber is in fluidic communication with the opening.

[0007] A method of making a hybrid spigot comprising a metal base and a thermoplastic body is also disclosed. The metal base defines a first bonding surface. The thermoplastic body includes a retaining structure for a coupler and a bonding flange defining a bonding interface surface. The thermoplastic body and optionally the metal base define a flow chamber disposed about a normal axis. The method comprises the step of laser-texturing a portion of the first bonding surface to form a plurality of microstructures therein. The plurality of microstructures include a plurality of undercut channels that are spaced apart from each other along a portion thereof. The thermoplastic body is then melt-bonded to the micro-textured region of the first bonding surface, such that a molten portion of the thermoplastic body at the bonding interface surface flows into the plurality of undercut channels defined in the metal base. After the step of melt-bonding, the molten portion of the thermoplastic body cools and hardens while within the plurality of undercut channels, thereby joining the thermoplastic body to the metal base.

[0008] These and other features of the disclosure will be more fully understood and appreciated by reference to the description of the embodiments and the drawings. Before the embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure may be implemented in various other embodiments and of being practiced or being conducted in alternativeways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the disclosure to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the disclosure any additional steps or components that might be combined with or into the enumerated steps or components.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective side view of a hybrid spigot including a metal base and a thermoplastic body welded to a fluidic system.

[0010] Figure 2 is a cross-sectional view of the hybrid spigot of Figure 1 along line 2-2.

[0011] Figure 3 is an isolated side view of a plurality of undercut channels formed on a first bonding surface of a metal base.

[0012] Figure 4A is an isolated top view of a plurality of undercut channels including parallel furrows on a first bonding surface of a metal base formed with successive laser passes.

[0013] Figure 4B is an isolated side view of a plurality of undercut channels including parallel furrows on a first bonding surface of a metal base formed with successive laser passes.

[0014] Figure 5 is an isolated perspective side view of the thermoplastic body ofthe hybrid spigot of Figure 1.

[0015] Figure 6 is an isolated perspective side view of the metal base of the hybrid spigot of Figure 1.

[0016] Figure 7 is an isolated perspective top view of the metal base of the hybrid spigot of Figure 1.

[0017] Figure 8 is an isolated perspective bottom view of the metal base of the hybrid spigot of Figure 1 illustrating a plurality of undercut channels on a first bonding surface of a metal base.

[0018] Figure 9A is slice cross-sectional view of an embodiment of a hybrid spigot comprising a metal base with a thermoplastic body over-molded thereon, the thermoplastic body including a bonding flange and a stabilization collar.

[0019] Figure 9B is slice cross-sectional view of an embodiment of a hybrid spigot comprising a metal base with a thermoplastic body over-molded thereon, the thermoplastic body including a first and a second portion.

[0020] Figure 10 is an isolated perspective side view of the metal panel of the fluidic system of Figure 1.

[0021] Figure 11 is a flow chart describing an exemplary method of making a hybrid spigot.DETAILED DESCRIPTION

[0022] A hybrid spigot and a method of manufacturing the hybrid spigot is provided. While discussed below in connection with a battery heat exchanger for use in a battery housing in an electric vehicle (“EV”), the hybrid spigot is suitable for a wide range of fluidic systems, inside and outside of EV applications, including applications such as heat exchangers for radiators, intercoolers, and inverters for cooling of power electronics.

[0023] Referring to Figures 1-9, wherein like numerals indicate corresponding parts throughout the several views, the hybrid spigot is illustrated and generally designated at 10. The hybrid spigot 10 can be manufactured efficiently, is light weight, and durable. Furthermore, the hybrid spigot 10 can be welded to a fluidic system 6 such as a metal heat exchanger without difficulty.

[0024] Referring now to Figure 1 , the hybrid spigot 10 comprises a metal base 12 and a thermoplastic body 14. The hybrid spigot 10 is for use with the fluidic system 6 defining an opening 8. A non-limiting example of one such fluidic system 6 is a heat exchanger or cooling plate.

[0025] The metal base 12 includes a first bonding surface 16, a second bonding surface 18, and an inner surface 20. The first bonding surface 16 includes a microtextured region 22 defining a plurality of undercut channels 24. Figure 6 is an isolated perspective side view of the metal base 12 of the hybrid spigot 10 of Figure 1. Figure 7 is an isolated perspective top view of the metal base 12 of the hybrid spigot 10 of Figure 1 whereas Figure 8 is an isolated perspective bottom view of the metal base 12 of the hybrid spigot 10 of Figure 1. Figure 7 illustrates a first flange portion 38 and a second flange portion 40 of the metal base 12. Figure 8 provides a view of the first bonding surface 16 including the micro-textured region 22 defining the plurality of undercutchannels 24. In many embodiments, the micro-textured region 22 defining the plurality of undercut channels 24 is bonded directly to the thermoplastic body such that a seal or an O-ring is not required to fluidically to prevent leaking of the cooling fluid from the flow chamber defined by the thermoplastic body 14 and the metal base 12.

[0026] Referring now to Figure 1, the thermoplastic body 14 has a proximal end 26, a distal end 28, an exterior surface 30, and an interior surface 32. For purposes of the subject disclosure proximal refers to situated nearer to the point of attachment to the fluidic system 6 whereas a distal refers to situated away from the point of attachment to the fluidic system 6. As such, a proximal direction means towards the point of attachment to the fluidic system 6 whereas a distal direction means away from the point of attachment to the fluidic system 6. Of course, proximally facing means facing towards the point of attachment to the fluidic system 6 whereas distally facing means facing away from the point of attachment to the fluidic system 6. Figure 10 is an isolated perspective side view of a metal panel of the fluidic system 6 illustrated in figure 1 , which defines an opening 8. The proximal end 26 of the hybrid spigot 10 is coupled or bonded to the fluidic system 6.

[0027] Referring now to Figures 1 and 5, the thermoplastic body 14 includes a bonding flange 34 and a retaining structure 42 for a coupler. The bonding flange 34 is at the proximal end 26 of the thermoplastic body 14 and defines a bonding interface surface 36. Referring now to Figure 2, a portion of the bonding interface surface 36 comprising the first thermoplastic composition that penetrates the plurality of undercut channels 24 the micro-textured region 22. The retaining structure 42 is spaced axially from the distal end 28 of the thermoplastic body 14. In some embodiments such as the embodiment of Figure 1, the inner surface 20 of the metal base 12 and the interior surface 32 of the thermoplastic body 14 define a flow chamber 44 disposed about anormal axis AN. In other embodiments such as the embodiment of Figures 9A and 9B, the interior surface 32 of the thermoplastic body 14 defines the flow chamber 44 disposed about the normal axis AN. That is, in some embodiments, the flow chamber 44 is defined entirely by the interior surface 32 of the thermoplastic body 14. When the second bonding surface 18 of the metal base 12 is attached to the fluidic system 6, the flow chamber 44 is in fluidic communication with the opening 8.

[0028] The retaining structure 42 can be integral with, melt-bonded, glued, or welded to the thermoplastic body. In the embodiments illustrated, the retaining structure is integral with the thermoplastic body 14. The retaining structure can be a distal portion of the thermoplastic body (e.g. for spin welding), a coupling flange configured for a molded connection, a clip-on connection, a bayonet connection, a spin welded connection, or a direct connection for use with a hose. In the embodiments illustrated, the retaining structure 42 is a coupling flange.

[0029] The metal base 12 comprises a metal such as aluminum, steel, copper, or alloys thereof. In the embodiment illustrated in Figures 1-8. In figure 6, the metal base 12 includes the first flange portion 38 and the second flange portion 40 adjacent to and distally spaced from the first flange portion 38. In this embodiment, the first flange portion 38 defines the first bonding surface 16 and the second flange portion 40 defines the second bonding surface 18. In this embodiment, the first and second bonding surfaces 16, 18 are proximally facing. Alternative embodiments may include a distally facing first bonding surface 16 and a proximally facing second bonding surface 18. In such an embodiment, the bonding interface surface 36 can be on the bonding flange 34 of the thermoplastic body and proximally facing and the micro-textured region 22 having the plurality of undercut channels 24 can be distally facing on the metal base 12. In such an embodiment, the first bonding surface 16 is opposite the second bondingsurface 18.

[0030] In many embodiments, the thermoplastic body 14 comprises a thermoplastic composition. The thermoplastic composition comprises a polymer selected from polyamide, polykeytone, and polypropylene. In some embodiments the thermoplastic composition comprises a polyamide (nylon) selected from the group of polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 6,6, polyamide 6,10, polyamide 6,12, and polyamide PPA. In a preferred example, the thermoplastic composition comprises polyamide 6 or polyamide 6,6. In some embodiments, the polymer is present in the thermoplastic composition in an amount of from 10 to 100, 35 to 95, or 60 to 85 wt. %, based on 100 parts by weight of the thermoplastic composition.

[0031] Some non- limiting examples of the thermoplastic composition are available under the trade names of ULTRADUR® and ULTRAMID®, which are commercially available from BASF of Florham Park, New Jersey. Other non-limiting examples of the thermoplastic composition are available under the trade name FRIANYL®, from Celanese of Dallas, TX. In one specific non-limiting example, the thermoplastic composition comprises ULTRADUR® B3wg6.

[0032] In many embodiments, the thermoplastic composition is flame-resistant. In one such embodiment, the thermoplastic composition complies with UL 94, the Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances testing, is a plastics flammability standard released by Underwriters Laboratories of the United States. The standard determines the material’s tendency to either extinguish or spread the flame once the specimen has been ignited. In some such embodiments the thermoplastic composition can have a UL 94 classification of HB, V- 2, V-l, V-0, 5VB, or 5VA. For embodiments with a V-0 rating, a sample of thethermoplastic composition is exposed to two 10 second combustion tests and flame goes out within 30 seconds, with no combustibles falling off. For embodiments with a V-l rating, a sample of the thermoplastic composition is exposed to two 10 second combustion tests, the flame goes out within 60 seconds, with no combustibles falling off. For embodiments with a V-2 rating, a sample of the thermoplastic composition is exposed to two 10 second combustion tests, the flame goes out within 60 seconds, but combustibles fall off. For embodiments with a HB rating, a sample of the thermoplastic composition is exposed to two 10 second combustion tests, and burning stops within 30 seconds on the sample with drops of vertical flammable thermoplastic composition allowed. For embodiments with a 5VB rating, a sample of the thermoplastic composition is exposed to two 10 second combustion tests, and there is fall off or drops of flaming thermoplastic composition, the sample can have a burn-through or hole subsequent to testing. For embodiments with a 5VA rating, a sample of the thermoplastic composition is exposed to two 10 second combustion tests, and there is no fall-off or drops of flaming thermoplastic composition, the sample cannot have a burn-through or hole subsequent to testing.

[0033] The thermoplastic composition may comply with CSA Standard C22.2 No. 0.17, Evaluation of Properties of Polymeric Materials, part of a series of Standards issued by CSA International under Part II of the Canadian Electrical Code. For example, in some such embodiments, a sample of the thermoplastic composition 3 to 13 mm thick may exhibit a combustion rate of less than 40 mm per minute. As another example, in some such embodiments, a sample of the thermoplastic composition less than 3 mm may exhibit a combustion rate of less than 70 mm per minute.

[0034] In some embodiments, the thermoplastic composition is thermally conductive and includes polyamide 6 (PA6). The thermoplastic composition of theseembodiments exhibits good electrical conductivity, electromagnetic shielding (EMI) and radio frequency (RF) shielding characteristics. In many embodiments, the thermoplastic composition comprises polyamide, is thermally conductive and can be injection molded or extruded. As such, the thermoplastic composition provides design freedom and excellent performance in applications previously restricted to metals.

[0035] Typically, the thermoplastic composition comprises a filler. Exemplary fillers include mineral fillers. Some non-limiting examples of mineral filler include particles and fibers comprising barites, calcium carbonate, carbon and carbon black, clays (e.g., kaolin clay), glass, mica, silica, talc, and wollastonite. In many embodiments, the thermoplastic composition comprises a fibrous filler selected from aramid fibers, carbon fibers, cellulose fibers, acrylic fibers, polyvinyl alcohol fibers, glass fibers, carbon nanotubes, and mineral fibers. In some embodiments, the thermoplastic composition comprises glass fibers, carbon fibers, graphite fibers, carbon nanotubes, or combinations thereof. In some embodiments, the filler is present in the thermoplastic composition in an amount of from 1 to 50, 10 to 40, or 15 to 35 wt. %, based on 100 parts by weight of the thermoplastic composition.

[0036] In some embodiments, the thermoplastic composition has a specific gravity of from 1.2 to 2.0, 1.3 to 1.4, 1.2 to 1.5, 1.4 to 1.8, 1.5 to 1.7, or 1.55 to 1.65 g / cm3, when tested in accordance with International Organization for Standardization (“ISO”) 1183-1:2019. In many embodiments, the thermoplastic composition has a melting temperature of from 210 to 310, 210 to 300, 260 to 290, or 230 to 290 °C, when tested in accordance with ISO 11357. In many embodiments, the thermoplastic composition has a melt volume-flow rate of from 30 to 40 cm3 / 10 min, when tested in accordance with ISO 1133.

[0037] The thermoplastic body 14 is bonded to the metallic base 12 by melt-bonding. In many embodiments, the thermoplastic body 14 can be bonded to the metallic base 12 by heating both the metallic base 12 and thermoplastic body 14, and contacting the molten bonding surface of the thermoplastic body 14 with the microtextured region 22 to secure the metal base 12. This contact (e.g., pressing together) allows the thermoplastic composition to melt and flow into or penetrate into the plurality of undercut channels 24 the micro-textured region 22 to secure the metal base 12 to the thermoplastic body 14. In some embodiments, the thermoplastic body 14 can be bonded to the metallic base 12 by hot-press welding or ultrasonic welding the thermoplastic body 14 to the metal base 12. In other embodiments, the thermoplastic body 14 can be bonded to the metallic base 12 by over-molding the thermoplastic body 14 to the metal base 12.

[0038] In other embodiments, the thermoplastic body 14 can be bonded to the metal base 12 via laser welding. From a welding perspective, the thermoplastic composition may be transparent, to varying degrees, to a laser beam having a particular wavelength. In some such embodiments, the thermoplastic composition can be characterized as transparent to laser wavelengths in the infrared and near-infrared spectrum. For example, the thermoplastic composition could be transparent to a laser beam having a wavelength of 808 nm or 980 nm. In many embodiments, the thermoplastic composition is transparent at a wavelength of from 800 to 1,000 nm. Once the laser beam passes through the thermoplastic composition it is converted into thermal energy at the interface between the thermoplastic body 14 and the metal base 12 because the metal base 12 absorbs the light energy of the laser beam to create heat and melt the thermoplastic composition.

[0039] During melt-bonding the bonding interface surface 36 of the thermoplastic body 14 penetrates into the plurality of undercut channels 24 the micro-textured region 22 to secure the metal base 12 to the thermoplastic body 14. The microtextured region 22 can be formed by laser-texturing the first bonding surface 16 of the metal base 12 to create microstructures therein, and subsequently melt-bonding the thermoplastic body 14 to the textured metal surface. In the current embodiment, the metal base 12 (and thus the first bonding surface 16) comprises a metal, for example aluminum, steel, copper, and alloys thereof. In many embodiments, the metal is a 2000, 3000, 40000, 5000, 6000, 7000, or 8000 series aluminum alloy. In one embodiment, the metal base 12 comprises a 3000 series aluminum alloy, which is aluminum alloyed with manganese. 3000 series aluminum alloys have higher strength than aluminum while maintaining good formability and corrosion resistance. Non-limiting examples of 3000 series aluminum include commercial grades 3004 and 3003. In another embodiment, the metal base 12 comprises a 5000 series aluminum alloy, which is a non-heat-treatable aluminum alloy with magnesium as its major alloying element. 5000 series aluminum alloys have exceptional strength and corrosion resistance. Nonlimiting examples of 5000 series aluminum include commercial grades 5083, 5052, 5754, and 5251. In many embodiments, the metal is a 2000, 3000, 40000, 5000, 6000, 7000, or 8000 series aluminum alloy. In one embodiment, the metal base 12 comprises a 3000 series aluminum alloy, which is aluminum alloyed with manganese. 3000 series aluminum alloys have higher strength than aluminum while maintaining good formability and corrosion resistance. Non-limiting examples of 3000 series aluminum include commercial grades 3004 and 3003. In another embodiment, the metal base 12 comprises a 5000 series aluminum alloy, which is a non-heat-treatable aluminum alloy with magnesium as its major alloying element. 5000 series aluminum alloys have exceptional strength and corrosion resistance. Non-limiting examples of 5000 series aluminum include commercial grades 5083, 5052, 5754, and 5251. The first bondingsurface 16 is micro-textured via continuous- wave or pulsed fiber laser etching to form a region having undercut grooves or channels 24.

[0040] As used herein, “micro-texturing” means the selective removal or melting of material from the surface of the metal sheet, resulting in channels, recesses, or grooves having an average depth of between 1 pm and 200 pm. For example, microtexturing the metal sheet can include forming a region of undercut grooves or channels 24 having an average depth of from 5 to 200 pm.

[0041] Micro-texturing can be performed via pulsed laser ablation or continuous -wave laser etching, by non- limiting example. As shown in Figure 3, the undercut grooves, or channels 24 may be spaced apart in parallel, such that no two channels 24 intersect. Alternatively, the undercut grooves or channels 24 may intersect each other, optionally in a quadrilateral arrangement. Alternatively, the undercut grooves or channels 24 may be an arrangement of radially spaced circular rings on the first bonding surface 16, as is illustrated in Figure 8.

[0042] Each groove or channel 24 includes an undercut, i.e., a width that increases in the depth- wise direction. For example, each undercut groove or channel 24 can include a surface opening defining a width of approximately 20 pm, increasing to a maximum width of approximately 40 pm at an intermediate point between the surface opening and the base of the groove or channel 24. In many embodiments, the plurality of undercut channels 24 define a width of from 5 pm to 50 pm. The undercut grooves or channels 24 can be spaced apart from each other by between 100 pm and 400 pm, for example, while other spacings can be used in other embodiments. To prevent interactions between adjacent grooves or channels 24, the ratio of channel width (e.g., the width at the surface opening) to channel separation (e.g., the distance between the midpoint of adjacent surface openings) can be at least 1:5, further optionally at least1:10. As discussed below, the undercut grooves or channels 24 promote improved polymer-to-metal adhesion, which provides a strong bond and obviates the need for fasteners.

[0043] Referring again to Figure 1, the retaining structure 42 is spaced axially from the distal end 28 of the thermoplastic body 14. In the embodiment illustrated, the retaining structure 42 is a coupling flange. Of course, the retaining structure 42 can be any shape (e.g., a channel, a tab(s), barbed, etc.) that allows the quick coupling of a house to the hybrid spigot 10. In another embodiment, the retaining structure 42 is barbed. That is, the exterior surface 30 of the thermoplastic body 14 has one or more continuous ridges or bumps, radially oriented, that are used to grip the inside diameter of a tube or pipe to create a fluidic connection.

[0044] Referring again to Figure 2, the hybrid spigot 10 can be attached to the fluidic system 6 via welding. More specifically, the second bonding surface 18 can be welded to an outer surface of the fluidic system 6. The second bonding surface 18 of the metal base 12 is positioned for attachment to the fluidic system 6 with the flow chamber 44 in fluidic communication with the opening 8. In the example illustrated, the second bonding surface 18 of the hybrid spigot 10 is welded to an aluminum plate of a heat exchanger. Figure 10 is an isolated perspective side view of the metal panel (e.g., aluminum) of the fluidic system (e.g., heat exchanger) of Figure 1. Of course, it should also be appreciated that the hybrid spigot 10 (in particular the metal base 12) can be, and is typically, welded to the thermoplastic plate. Attachment of the hybrid spigot 10 to the fluidic system 6 can also be achieved via various mechanical fastening means. For example, the second bonding surface 18 of the metal base 12 can define a sealing ring channel into which an O-ring can be inserted and the hybrid spigot 10 can be bolted to the fluidic system 6.

[0045] In some embodiments, the thermoplastic body 14 includes a stabilization collar 46. Referring now to Figure 9A, a slice cross-sectional view of an embodiment of the hybrid spigot 10 comprising the metal base 12 with the thermoplastic body 14 over- molded thereon is illustrated. In this embodiment, the thermoplastic body 14 includes the bonding flange 34, which presents the bonding interface surface that is bonded to (and penetrates) the plurality of undercut channels 24 of the micro-textured region 22 of the first bonding surface 16 the first flange portion 38 of the metal base 12. The thermoplastic body 14 also includes the stabilization collar 46. The stabilization collar 46 contacts the surface that is opposite the first bonding surface 16 of the first flange portion 38 of the metal base 12 (in this example the top surface of the first flange portion 38 of the metal base 12). As such, the first flange portion 38 of the metal base 12 is received between the bonding flange 34 and the stabilization collar 46. This embodiment of the hybrid spigot 10 is typically made by over-molding the thermoplastic body 14 (a single piece) onto the metal base 12.

[0046] Referring now to Figure 9B, a slice cross-sectional view of an embodiment of the hybrid spigot 10 comprising the metal base 12 with the thermoplastic body 14 over- molded thereon is illustrated. In this embodiment, the thermoplastic body 14 also includes the bonding flange 34 and the stabilization collar 46. The bonding flange 34 presents the bonding interface surface that is bonded to (and penetrates) the plurality of undercut channels 24 of the micro-textured region 22 of the first bonding surface 16 the first flange portion 38 of the metal base 12. The stabilization collar 46 contacts the surface that is opposite the first bonding surface 16 of the first flange portion 38 of the metal base 12 (in this example the top surface of the first flange portion 38 of the metal base 12). As such, the first flange portion 38 of the metal base 12 is received between the bonding flange 34 and the stabilization collar 46.

[0047] In contrast to the embodiment of Figure 9A, the embodiment of Figure9B includes the thermoplastic body 14 comprising a first portion 14A, and a second portion 14B. In the embodiment of Figure 9B, the first portion 14A of the thermoplastic body 14 is over-molded on the metal base 12. The metal base 12 having the first portion 9A molded thereon is then welded to the fluidic system 6. In turn, the second portion 14B is melt bonded (e.g., spin-welded) on the first portion 14A to form the thermoplastic body 14. This embodiment provides design flexibility and allows for the coupling of various structures to the first portion, e.g., a 90° elbow, which would interfere with the welding of the hybrid spigot 10 to the fluidic system 6.

[0048] In some embodiments, the thermoplastic body 14 includes a seal channel which is shaped to receive an O-ring to provide a fluidic seal with the source of the cooling fluid. In included the flow channel is typically included at the distal end of the hybrid spigot 10.

[0049] In some embodiments, the thermoplastic body 14 includes a locator 48, the locator 48 can comprise one or more projections that ensure that the flow chamber 44 aligns with the opening 8 of the fluidic system 6. The one or more projections extend in a proximal direction past the second bonding surface 18 of the metal base 12. In order for the hybrid spigot 10 to sit flush on the surface of the fluidic system 6, the one or more projections must be received in the opening such that the flow chamber 44 aligns with the opening of the fluidic system 6. In the embodiment of Figures 9A and 9B, the locator 48 comprises a circular projection that corresponds with the inner diameter of the opening, i.e. fits in the opening. In other examples, the proximal end of the thermoplastic body 14 can include two or more, e.g., 3, tabs that extend in a proximal direction past the second bonding surface 18 of the metal base 12. It should be appreciated that the shape of the opening can vary and thus the location and shape ofthe locator will vary to correspond to the specific shape of the opening.

[0050] Referring now to Figure 11, a method 100 of making the hybrid spigot 10 comprising the metal base 12 and the thermoplastic body 14, as they are described above, is also disclosed. The method comprising the steps of: micro-texturing a portion of the first bonding surface 16 to form a plurality of microstructures therein, the plurality of microstructures including a plurality of undercut channels 24 that are spaced apart from each other along a portion thereof 102; melt-bonding the thermoplastic body 14 to the micro-textured region 22 of the first bonding surface 16 of the metal base 12, such that a molten portion of the thermoplastic body 14 at the bonding interface surface 36 flows into the plurality of undercut channels 24 defined in the metal base 12 (104); and permitting the molten portion of the thermoplastic body 14 to harden while within the plurality of undercut channels 24, thereby joining the thermoplastic body 14 to the metal base 12 (106).

[0051] As is described above, the step of laser-texturing 102 can be performed via laser ablation or continuous wave laser etching. Pulsed laser ablation can be performed using excimer lasers and solid-state lasers such as the Nd:YAG laser. Continuous-wave laser etching can be performed using a 1000 W laser with a 25-50 pm focal spot size. Forming the undercut grooves or channels 24 is achieved with successive passes of the laser per groove or channel, optionally at least three passes per groove or channel. Undercut microstructures may also be created using successive lines of laser-generated melting to create furrows with wavelike ripples, shown in Figure 4 for example.

[0052] After forming a micro-textured region 22 of the metal surface, the step of melt-bonding 104 the thermoplastic body 14 to the micro-textured region 22 of thefirst bonding surface 16 of the metal base 12 can, in many embodiments, be performed via welding or co-molding (e.g., over- molding). More specifically, various embodiments of this step this step can include hot-press welding the plastic component to the metal surface, injection over-molding the plastic component to the metal surface, ultrasonically welding the plastic component to the metal surface, or laser welding, depending on the polymer selected for the given application. Hot-press welding includes heating the first bonding surface 16 comprising the thermoplastic composition and the micro-textured region 22 of the bonding interface surface 36 comprising metal until the thermoplastic composition melts, and concurrently or subsequently pushing the first bonding surface 16 and the bonding interface surface together, e.g., within a press. Heating can be performed according to any desired method, including laser heating, induction heating, hot plate heating, or more simply by conduction heating through the metal component. Interface pressures of between 1 MPa and 3 MPa can assure a pressure-tight weld. In the embodiment of Figure 1 , the thermoplastic body 14 is first molded (e.g., injection molded) and is then welded to the metal base 12. The gap between the outer surface of the thermoplastic body 14 and the inner surface 20 of the first flange portion 38 of the metal base 12 is required to accommodate the retaining structure 42, which is a coupling flange in this example.

[0053] Ultrasonic welding includes the application of ultrasonic waves at the plastic-metal interface, resulting in localized heating of the interface. Compression forces are applied to allow bonding to occur, typically via a sonotrode tip and anvil. Ultrasonic welding can be used in applications where the thermoplastic body 14 is formed from PK, PP, PA6, or PA66, though other plastics can also be used.

[0054] Injection over-molding includes over molding the thermoplastic body 14 directly onto the metal base 12, such that molten thermoplastic compositionpenetrates the undercut grooves and channels 24 and hardens under high pressures to conform to the micro-textured region 22 of the bonding interface surface comprising metal. In the embodiment of Figure 9A, the thermoplastic body 14 is over-molded to the metal base 12. As such, there is no need for a gap between the outer surface of the thermoplastic body 14 and the first flange portion 38 of the metal base 12 to accommodate the retaining structure 42, which is a coupling flange in this example.

[0055] In the application of these joining techniques, the thermoplastic composition of the first bonding surface 16 softens / melts and penetrates into the undercut grooves or channels 24 and conforms to the micro-textured region 22 of the bonding interface surface 36 comprising metal against which it is contacted. After hardening inside the undercut grooves or channels 24, the thermoplastic body 14 and the metal base 12 are now joined. As a result, a fastener or snap connection is not required, and the thermoplastic body 14 adheres to the metal base 12 as a hybrid component. The micro-textured interface provides a hermetic seal, which provides a barrier to cooling fluids, for example water, glycol-based fluids, oil, and air.

[0056] In one embodiment, melt-bonding the first bonding surface 16 of the thermoplastic body 14 to the micro-textured region 22 of the metal base 12 comprises contacting the thermoplastic body 14 and the metal base 12 to form an interface between the first bonding surface 16 and the bonding interface surface 36; and contacting the bonding interface surface 36 of the bonding flange 34 with a laser beam such that the laser beam travels through the bonding flange 34, to melt the thermoplastic composition at the interface and weld the thermoplastic body 14 and the metal base 12 to form the hybrid spigot 10. In this embodiment, the steps of contacting the thermoplastic body 14 and the metal base 12 to form an interface between the first bonding surface 16 and the bonding interface surface 36 and contacting the bondinginterface surface 36 of the bonding flange 34 with a laser beam can be conducted robotically.

[0057] Of course, the method 100 may also comprise the step of joining the hybrid spigot 10 to the fluidic system 6 such as a cold plate or heat exchanger. The step of joining may be further defined as securing the second bonding surface 18 of the metal base 12 to a metal or thermoplastic surface of the fluidic system 6. The step of joining may comprise welding the second bonding surface 18 of the metal base 12 to a metal or thermoplastic surface of a heat exchanger. More specifically, the second bonding surface 18 can be welded to an outer surface of the fluidic system 6. The second bonding surface 18 of the metal base 12 is positioned for attachment to the fluidic system 6 with the flow chamber 44 in fluidic communication with the opening 8. In the example illustrated, the second bonding surface 18 of the hybrid spigot 10 is welded to an aluminum plate of a heat exchanger. Of course, it should be appreciated that the hybrid spigot 10 can also be welded to thermoplastic plate. Attachment of the hybrid spigot 10 to the fluidic system 6 can also be achieved via various mechanical fastening means. For example, the second bonding surface 18 of the metal base 12 can define a sealing ring channel into which an O-ring can be inserted and the hybrid spigot 10 can be bolted to the fluidic system 6.

[0058] The above description is that of current embodiments of the disclosure. Various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connectionwith these embodiments. For example, and without limitation, any individual element(s) of the described disclosure may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present disclosure is not limited to only those embodiments that include all these features or that provide all the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

CLAIMS1. A hybrid spigot for use with a fluidic system defining an opening, said hybrid spigot comprising: a metal base including a first bonding surface, a second bonding surface, and an inner surface, the first bonding surface including a micro-textured region defining a plurality of undercut channels; and a thermoplastic body having a proximal end, a distal end, an exterior surface, and an interior surface, the thermoplastic body including: a bonding flange at the proximal end defining a bonding interface surface, a portion of the bonding interface surface penetrating the plurality of undercut channels the micro-textured region; and a retaining structure for a coupler, the retaining structure spaced axially from the distal end; wherein the interior surface of the thermoplastic body defines a flow chamber disposed about a normal axis, and wherein the second bonding surface of the metal base is positioned for attachment to the fluidic system with the flow chamber in fluidic communication with the opening.

2. The hybrid spigot of claim 1 , wherein the plurality of undercut channels have: a width of from 5 pm to 50 pm; a depth of from 1 pm to 200 pm; and / or are spaced apart from each other by from 100 pm to 400 pm.

3. The hybrid spigot of claim 1, wherein the plurality of undercut channels define a ratio of channel width to channel spacing of at least 1:5, the channel spacing being a distance separating adjacent ones of the plurality of undercut channels.

4. The hybrid spigot of claim 3, wherein the metal base comprises aluminum, steel,copper, or alloys thereof.

5. The hybrid spigot of claim 1, wherein the retaining structure is a coupling flange.

6. The hybrid spigot of claim 1 , wherein the first bonding surface is opposite the second bonding surface.

7. The hybrid spigot of claim 1, wherein the first and second bonding surfaces are proximally facing.

8. The hybrid spigot of claim 7, wherein the metal base includes a first flange portion and a second flange portion adjacent to and distally spaced from said first flange portion.

9. The hybrid spigot of claim 8 wherein the first flange portion defines the first bonding surface, and the second flange portion defines the second bonding surface.

10. The hybrid spigot of claim 1, wherein the proximal end of the thermoplastic body includes a locator which is shaped to he received by the opening defined by the fluidic system to ensure that the flow chamber aligns with the opening of the fluidic system.

11. The hybrid spigot of claim 1, wherein the thermoplastic body includes a stabilization collar in contact with the metal base.

12. The hybrid spigot of claim 1, wherein the thermoplastic body comprises a thermoplastic composition comprising a polymer selected from polyamide, polykeytone, and polypropylene.

13. The hybrid spigot of claim 12, wherein the thermoplastic composition comprises a polyamide selected from polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 6,6, polyamide 6,10, polyamide 6,12, and polyamide PPA and a fibrous filler selected from aramid fibers, carbon fibers, cellulose fibers, acrylicfibers, polyvinyl alcohol fibers, glass fibers, mineral fibers.

14. The hybrid spigot of claim 12, wherein the thermoplastic composition has a UL 94 classification of V-l or V-0.

15. The hybrid spigot of claim 1, wherein the fluidic system is further defined as a heat exchanger.

16. A method of making a hybrid spigot comprising a metal base defining a first bonding surface and a thermoplastic body including a retaining structure for a coupler and a bonding flange defining a bonding interface surface, said method comprising the steps of: laser-texturing a portion of the first bonding surface 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 region thereof; melt-bonding the thermoplastic body to the plurality of undercut channels of the first bonding surface, such that a molten portion of the thermoplastic body at the bonding interface surface flows into the plurality of undercut channels defined in the metal base; and permitting the molten portion of the thermoplastic body to harden while within the plurality of undercut channels, thereby joining the thermoplastic body to the metal base, wherein the thermoplastic body and the metal base define a flow chamber for a cooling fluid disposed about a normal axis.

17. The method of claim 16, wherein laser-texturing is performed via laser ablation or continuous wave laser etching and with at least three passes of laser energy.

18. The method of claim 16, wherein melt-bonding the thermoplastic body includes hot-press welding or ultrasonic welding the thermoplastic body to the metal base.

19. The method of claim 16, wherein melt-bonding the thermoplastic body includesover-molding the thermoplastic body to the metal base.

20. The method of claim 19, wherein the thermoplastic body comprises a first portion and a second portion and wherein melt-bonding the thermoplastic body includes over-molding the first portion of the thermoplastic body to the metal base, and the method further includes the steps of: welding or braising the metal base with the first portion molded thereon to a fluidic system: and melt bonding the second portion of the thermoplastic body to the first portion of the fluidic system.

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