Method of manufacturing an eutectic beam having multi-functional support members

A method of manufacturing an eutectic beam which includes a U-shaped evaporator tube having first and second spaced leg portions, and a housing, comprising the steps of:

• providing plastic support means which includes a generally cylindrical portion having support legs which extend outwardly therefrom, with the cylindrical portion defining an opening dimensioned to enable the support means to snugly but slidably surround a leg portion of the evaporator tube, and with the support legs having first ends integral with the cylindrical portion and second ends opposite the first ends,
• providing a rotational mold which includes cooperative mold parts having surfaces which defined a cavity, with the rotational mold including a wall portion having openings through which ends of the first and second spaced leg portions of the evaporator tube extend when the evaporator tube is assembled within the rotational mold,
• placing the plastic support means on the evaporator tube to snugly but slidably surround the first and second spaced leg portions of the evaporator tube,
• placing the U-shaped evaporator tube in a cooperative mold part of the rotational mold,
• assembling the cooperative mold parts of the rotational mold about the U-shaped evaporator tube such that the second ends of the support legs of the plastic support means contact predetermined inner surfaces of the mold cavity defined by the cooperative mold parts and such that the ends of the first and second leg portions of the evaporator tube extend through the openings defined in the wall portion of the rotational mold, to thereby position the evaporator tube within the mold cavity by means of the openings in the wall portion of the rotational mold through which the ends of the first and second leg portions of the evaporator tube extend, and by means of the second ends of the support legs of the plastic support means which contact the predetermined inner surface of the mold cavity,
• and rotationally molding a plastic material within and against predetermined inner surfaces of the mold cavity to provide a plastic housing in spaced relation about the first and second spaced leg portions of the evaporator tube and thus form the eutectic beam, such that the support legs of the plastic support means extend through the space between the first and second leg portions of the evaporator tube and the plastic housing, and such that only the second ends of the support legs of the plastic support means become embedded in wall portions of the molded plastic housing, whereby the support legs of the plastic support means additionally provide positional support for the evaporator tube located within the rotationally molded plastic housing during use of the eutectic beam comprising the evaporator tube and the rotationally molded plastic housing.