Overmolding insert for heat exchanger, process for manufacturing a heat exchanger, and heat exchanger produced thereby

A heat exchanger, comprising

• a plurality of hollow conduits each having a first end and a second end;
• a first manifold having an internal space, said first manifold connected to said first end of each conduit such that said hollow conduit is in communication with said internal space;
• a second manifold connected to said second end of each conduit;
• wherein at least one of said first and second manifolds is joined around said conduit ends and at least one overmolding insert such that a hollow conduit is fitted over a hollow projection,
• wherein said overmolding insert comprises a base having at least one first opening in a first surface, each said first opening being in communication with a corresponding second opening in a second surface opposite said first surface,
• at least one hollow projection extending from said first surface of said base, said hollow projection having a first opening in communication with the first opening of said first surface and a second opening located at a terminal portion of said hollow projection,
• said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space,
• wherein said terminal portion of said hollow projection extends beyond said partially closed space.

An overmolding insert, consisting of:

• a base having a plurality of first openings in a first surface, said first openings being in communication with a plurality of second openings in a second surface opposite said first surface,
• a plurality of hollow projections extending from said first surface of said base, each said hollow projection having a first opening in communication with said first opening of said first surface and a second opening located at a terminal portion of said hollow projection,
• said insert further comprising two opposed side walls, each side wall being joined to said first surface, two opposed end walls being joined to opposite ends of said first surface and extending from one side wall to the other side wall, such that the side walls, the end walls, and the first surface define a partially closed space,
• wherein said terminal portions of said hollow projections extend beyond said partially closed space.