Port flange for a heat exchanger and method of making a port flange

A port flange for a heat exchanger, comprising:

• a heat exchanger mounting portion;
• a system interface portion;
• at least one port channel connecting respective openings in the heat exchanger mounting portion and the system interface portion;
• and
• at least one mounting recess which is accessible from the system interface portion, wherein the port flange presents a space situated between the port channel and the mounting recess, and wherein the space has lower density than at least one of the heat exchanger mounting portion or the system interface portion, and wherein the heat exchanger mounting portion is formed from a generally planar member having a thickness which is less than a total thickness of the port flange.

A port flange for a heat exchanger, comprising:

• a heat exchanger mounting portion configured to connect to a heat exchanger plate;
• a system interface portion comprising a flange configured to connect to a system that is to supply or receive a medium to/from the heat exchanger;
• and
• a port channel configured to connect an opening in the system interface portion to the heat exchanger mounting portion, wherein at least part of the port channel is formed from a first piece of material, and wherein the flange is formed of a second piece of material, and wherein the first piece of material is permanently joined to the second piece of material.

A heat exchanger having at least one port flange, the at least one port flange comprising:

• a heat exchanger mounting portion configured to connect to a heat exchanger plate;
• a system interface portion comprising a flange configured to connect to a system that is to supply or receive a medium to/from the heat exchanger;
• and
• a port channel configured to connect an opening in the system interface portion to the heat exchanger mounting portion, wherein at least part of the port channel is formed from a first piece of material, and wherein the flange is formed of a second piece of material, and wherein the first piece of material is permanently joined to the second piece of material as claimed in any one of the preceding claims mounted thereon.

A method of forming a port flange for a heat exchanger, the flange comprising a system interface portion, a port channel extending from a first opening in the system interface portion, and at least one mounting recess extending from a second opening in the system interface portion, the method comprising:

• providing a first part defining the system interface portion and having the first opening and the second opening;
• providing a sleeve defining a recess;
• permanently joining the sleeve to the first part such that the first or second opening provides access to the recess, thus forming at least one of the port channel or the at least one mounting recess;
• and
• providing the other one of the port channel or the mounting recess such that the port flange presents a space situated between the port channel and the mounting recess, wherein the space has a lower density than one or more of the heat exchanger mounting portion or the system interface portion.