Patent Description:
<FIG> illustrates a conventional battery cooler <NUM>. The conventional battery cooler <NUM> includes multiple microchannel tubes <NUM> of aluminum formed by extrusion. Each microchannel tube <NUM> includes multiple channels 2a. For example, the conventional battery cooler as disclosed in <CIT> includes tubes <NUM> that are disposed adjacent to one another along a first direction x in spaced apart configuration to define battery-accommodating space that receives battery "b" to be cooled. The microchannel tube or tube <NUM> is connected to a header that forms a part of the tank <NUM> by brazing, such configuration configures fluid communication between the metallic tank <NUM> and the tubes <NUM>. However, the brazing of the microchannel tube <NUM> to the tank <NUM> is a problem. The inherent heating of the microchannel tube or tube <NUM> during the brazing process, is detrimental to the mechanical properties, particularly, the mechanical resistance of the microchannel tubes <NUM>. Furthermore, the microchannel tube <NUM> is un-necessarily heated in the brazing furnace wherein only the ends of the microchannel tube is required to be subjected to heating for brazing and securely connecting the ends of the microchannel tube <NUM> to the tank <NUM>. There are further disadvantages of subjecting the entire microchannel tube <NUM> to brazing in brazing furnace, for example, there is wastage of energy and need for larger brazing furnaces when the entire microchannel tubes <NUM> are subjected to the brazing in the brazing furnace. Further, the brazing process involves other problems such as CO<NUM> emissions that renders the working environment hazardous for workers and causes harm to the environment. Further, brazing requires furnaces, jigs and fixtures and is uneconomical. Further, as brazing connection necessitates the components to be joined to be metallic and involves fused metal deposits, thereby increasing the overall weight of the components. Accordingly, brazing connection is particularly undesirable in case of components assembled in vehicle as increase in overall weight of the vehicle reduces overall fuel economy of the vehicle. The microchannel tubes <NUM> is coated with powder coating of thermally conductive but electrically insulated material, except at the end portions thereof to avoid clogging of the channels 2a. The coating of thermally conductive but electrically insulated material permits heat transfer from the batteries to the coolant flowing through the microchannel tubes while sill prevent electric current from flowing from the batteries to the coolant through the microchannel tubes. However, irregular surfaces that are inherently formed at the interface between portions of the microchannel tube that are powder coated and that are not cause problems such as brazing defects.

Most of the prior art suggests brazing connection between the microchannel tubes <NUM> and the tank <NUM>. Although, few of the prior art suggest mechanical connections between the microchannel tubes <NUM> and the tank <NUM> to avoid brazing for forming secure connection between the microchannel tubes <NUM> and the tank <NUM>. However, such mechanical connections are not efficient and causes leakage of the coolant from the battery cooler <NUM>, the leakage issues may further lead to inefficient operation of the battery cooler <NUM>.

Accordingly, there is a need for battery cooler that prevents brazing for configuring connection between the microchannel tubes and the tank, thereby obviating drawbacks associated with the brazing such as for example, unnecessary heating of the entire microchannel tubes, energy losses, increase in overall weight of the battery cooler and air pollution caused by brazing. Further, there is a need for a battery cooler that utilizes over-molding and mechanical connections for configure secure and leak proof connection between the microchannel tubes and the tank.

An object of the present invention is to provide a battery cooler that prevents brazing for configuring connection between the microchannel tubes and the tank, thereby preventing the drawbacks associated with the brazing for configuring the connection.

Yet another object of the present invention is to provide a battery cooler that utilizes over-molding and mechanical connections for configuring secure and leak proof connection between the microchannel tubes and the tank.

Still another object of the present invention is to provide a battery cooler that maintains efficiency and performance of the battery cooler by preventing leakage of coolant.

Yet another object of the present invention is to provide a battery cooler that is comparatively lighter in weight compared to conventional battery coolers that involves brazing for forming connection between tank and microchannel tubes.

Still another object of the present invention is to provide a battery cooler that is environment friendly and involves comparatively less carbon footprint compared to conventional battery coolers that involves brazing for forming connection between tank and microchannel tubes.

A battery cooler is disclosed in accordance with an embodiment of the present invention. The battery cooler includes at least one microchannel tube, a tank holder, a tank and a sealing gasket. The microchannel tube includes respective multiple channels and is formed by extrusion. The tank holder is secured to the microchannel tube. The tank is securely mounted over the tank holder. The sealing gasket is secured to at least one of the microchannel tube and the tank holder. The tank holder is over-molded over extreme ends of the microchannel tube and the tank is secured to the tank-holder by mechanical connections.

Generally, the microchannel tubes follows a wavy profile along length thereof, crests formed on microchannel tubes disposed adjacent to one another along a first direction orthogonal to the plane of the microchannel tubes are aligned and disposed opposite to one another define battery accommodating space to receive battery to be cooled.

Particularly, at least a portion of the periphery of extreme ends of the microchannel tube is formed with retainer elements, for example, corrugations, teeth etc. to ensure gripping of the microchannel tube by the tank-holder over-molded over the microchannel tube.

According to the invention, the microchannel tubes disposed adjacent to each other in a second direction Z along the plane thereof are separated by a connection portion formed with at least one opening to facilitate over-molding of the tank-holder over the corresponding microchannel tube.

In accordance with another embodiment, the battery cooler includes a single microchannel tube disposed along the second direction Z. The microchannel tube is formed with at least one separating means such as a filled channel and a connecting portion to define separate fluid flow passes for U-flow through the channels. At least one of the filled channel and the connecting portion is configured with at least one opening to facilitate over-molding of the tank holder over the corresponding microchannel tube.

Specifically, the tank includes at least one peripheral wall, an inlet, an outlet and a connecting opening. The peripheral wall defines an enclosure. The inlet and the outlet is for ingress and egress of a fluid with respect to the enclosure. The connecting opening is defined by the peripheral wall, receives and holds at least one corresponding microchannel tube to configure fluid communication between the enclosure and the microchannel tube.

Also, the tank includes either one of an internal baffle and recesses to divide an interior of the tank into a first tank portion and a second tank portion separate from the first portion.

Generally, the sealing gasket is secured to the extreme end of the at least one of microchannel tube by at least one of press-fitting and over-molding.

Particularly, the sealing gasket is of resilient material, for example, Ethylene Propylene Diene Monomer (EPDM) material and is compressed as the tank is securely mounted on the tank holder.

Generally, at least one of the tank holder and the sealing gasket is disposed between the microchannel tube and the tank.

Particularly, at least one of the tank holder and the sealing gasket is coaxially received with respect to the microchannel tubes.

In accordance with an embodiment of the present invention, the tank holder includes a groove formed thereon to receive and securely hold the sealing gasket therein.

Generally, the mechanical connections include complementary snap engagement elements formed on the tank holder and the tank respectively.

Particularly, the tank includes a plurality of latching element formed along the length thereof and that is received in and engages with corresponding loops formed on the tank holder to securely mount the tank to the tank holder.

More specifically, at least one of the microchannel tubes is coated with powder coating of thermally conductive and electrically insulated material, except at the end portions thereof.

Further, the tank holder covers the interface between portions of the microchannel tube without the powder coating and with the powder coating respectively.

Also, the peripheral wall extends beyond the connecting opening to cover the extreme ends of the microchannel tubes.

Also is disclosed a method for assembling a battery cooler in accordance with an embodiment of the present invention. The method includes the step of powder coating at least a portion of at least one microchannel tube with thermally conductive and electrically insulated material. Thereafter the method involves the step of over-molding a tank holder over at least one extreme end of a microchannel tube such that the tank holder covers interface between portions of microchannel tube without coating and with coating respectively. Thereafter, the method includes the step of step of securely mounting a sealing gasket over at least one of tank holder and the microchannel tube. Finally, the method includes the step of securely mounting a tank over the corresponding tank holder.

Although the present invention is explained in the forthcoming description and accompanying drawings with an example of a battery cooler, wherein the battery cooler includes at least one microchannel tube, a tank holder, a tank and a sealing gasket. The microchannel tube includes respective multiple channels and is formed by extrusion. The tank holder is secured to the microchannel tube and the tank is securely mounted over the tank holder. Particularly, the tank holder is over-molded over extreme ends of the microchannel tube and the tank is secured to the tank-holder by mechanical connections. However, the present invention is applicable for any heat exchanger for use in vehicular and non-vehicular environments, wherein it is required to configure a secure and leak-proof connection between the tank and the micro-channel tubes without brazing, thereby preventing the drawbacks associated with brazing process for configuring connection between the tank and the microchannel tubes.

The present disclosure envisages a battery cooler <NUM> as illustrated in <FIG>. Particularly, FIF. <NUM> illustrates a side view of at least a portion of the battery cooler <NUM>, wherein batteries "B" to be cooled are depicted disposed between adjacent microchannel tubes <NUM> of the battery cooler <NUM>. The battery cooler <NUM> generally includes at least one microchannel tube-tank assembly. <FIG> illustrates isometric view of a microchannel tube-tank assembly. <FIG> illustrates an exploded view of the microchannel tube-tank assembly. Particularly, the battery cooler <NUM> includes at least one microchannel tube <NUM>, a tank holder <NUM>, a tank <NUM> and a sealing gasket <NUM>.

Referring to <FIG>, each microchannel tube <NUM> includes multiple channels 10a and is formed by extrusion. In a preferred embodiment, a pair of microchannel tubes <NUM> are arranged co-planar to each other as illustrated in the <FIG>, wherein one microchannel tube <NUM> defines a coolant pass and the other microchannel tube <NUM> define a return pass. Particularly, the pair of microchannel tubes <NUM> are disposed adjacent and parallel to another pair of microchannel tubes disposed along a first direction X orthogonal to the plane of the microchannel tubes <NUM> as illustrated in <FIG>. The pair of microchannel tubes <NUM> are disposed spaced apart from each other to define battery-accommodating space there between to receive batteries "B" to be cooled by the battery cooler <NUM>. More specifically, each of the microchannel tubes <NUM> follows a wave profile along length thereof such that crests 10d formed on microchannel tubes <NUM> disposed adjacent to one another along the first direction X are aligned and disposed opposite to one another to define battery accommodating spaces to receive the batteries "B" to be cooled. The pair of microchannel tubes <NUM> disposed adjacent to each other in a second direction Z along the plane of the microchannel tubes <NUM> are connected to and in fluid communication with the tank <NUM>.

<FIG> illustrates isometric view and section view of the tank <NUM>. The tank <NUM> is formed of glass reinforced plastic material and holds coolant therein. Such configuration of the tank <NUM> imparts strength to the tank in order to enable the tank <NUM> withstand even high pressure fluid, particularly coolant. The tank <NUM> includes a first portion 30a and a second portion 30b as illustrated in <FIG>. More specifically, the tank <NUM> includes either one of an internal baffle and recesses to divide the interior of the tank <NUM> into the first portion 30a and the second portion 30b that is separate from the first portion 30a. The first portion 30a receiving coolant from an inlet 32a formed on the first portion 30a distributes the coolant to a first microchannel tube <NUM>. The adjacent microchannel tubes <NUM> disposed along the same plane are connected to and in fluid communication with each other by virtue of an intermediate connecting tank <NUM> disposed opposite to the tank <NUM>. The intermediate connecting tank <NUM> forms u-flow between the adjacent microchannel tubes <NUM> disposed along the same plane. The intermediate connecting tank <NUM> collects coolant from the first microchannel tube and directs the same to the second microchannel tube, wherein the second microchannel tube <NUM> defines the return pass of the coolant. The coolant flowing through the first and second microchannel tubes <NUM> extracts heat from the batteries "B" disposed between the adjacent microchannel tubes <NUM> disposed parallel to each other along the first direction X. The coolant after extracting heat from the batteries "B" is collected in the second portion 30b of the tank <NUM> and egresses through an outlet 32b formed on the tank <NUM>, particularly, the second portion 30b.

In accordance with an embodiment, the battery cooler <NUM> includes a single microchannel tube disposed along the second direction Z. The microchannel tube <NUM> is formed with at least one of a filled channel and a connecting portion to define separate fluid flow passes for U-flow through the channels. At least one of the filled channel and the connecting portion is configured with at least one opening to facilitate over-molding of the tank holder over the corresponding microchannel tube. Particularly, the microchannel tubes <NUM> are arranged with each microchannel tube disposed parallel to each other in different planes in a first direction X to define battery accommodating space therebetween to configure the battery cooler. In such arrangement of the microchannel tubes, each microchannel tube configures the u-flow path the coolant flow with itself. Particularly, few channels of at least one of the microchannel tubes <NUM> disposed parallel to each other define coolant pass and remaining channels of the same microchannel tube <NUM> define return pass of the coolant. The channels 10a defining the coolant pass and return pass and interconnected by the tank <NUM> and the intermediate connecting tank <NUM> and for the sake of brevity of the present document is not explained in details.

In case of the conventional battery cooler, the microchannel tube and the tank formed of metal and connected to each other by brazing face various problems associated with brazing connection between the microchannel tubes and the tank.

In order to avoid brazing and prevent the problems associated with the brazing process for configuring fluid tight connection between the microchannel tubes and the tank, the battery cooler <NUM> of the present invention utilizes a combination of over-moulding and mechanical connections for configuring secure connection between the microchannel tube and tank. By preventing brazing connection between the tank and the microchannel tubes, the battery cooler <NUM> of the present invention is comparatively lighter and manufactured in comparatively convenient, economic and environmentally friendly manner compared to conventional battery coolers that involve brazing connection between the tank and the microchannel tubes. The tank-microchannel assembly in case of the battery cooler <NUM> of the present invention involves configuring the tank holder <NUM> as illustrated in <FIG> on extreme ends of the microchannel tube <NUM> and thereafter securing the tank <NUM> to the tank holder <NUM>. Particularly, the tank holder <NUM> is securely formed on at least one of the extreme ends of the microchannel tube <NUM> by over-molding and the tank <NUM> is securely mounted on the tank holder <NUM> by using mechanical connections such as for example latching elements <NUM>. <FIG> illustrates an isometric view of the microchannel tube-tank assembly without the tank <NUM> depicting internal details such as the tank holder <NUM> and the sealing gasket <NUM> secured to one end of the microchannel tubes by over-molding.

Several provisions are provided to securely form the tank holder <NUM> at the end portions of the corresponding microchannel tube <NUM>. Particularly, retainer elements are formed for retaining the tank holder <NUM> on the extreme end of the microchannel tube <NUM>. In accordance with an embodiment, at least a portion of the periphery of extreme ends of the microchannel tube <NUM> is formed with corrugations <NUM> to ensure proper gripping connection between the microchannel tube <NUM> and the tank-holder <NUM> over-molded over the microchannel tube <NUM>. Generally, the corrugations <NUM> are horizontal corrugations that are uniformly spaced with respect to each other. Alternatively, the corrugations <NUM> are vertical corrugations that are uniformly spaced with respect to each other. The corrugations <NUM> can be uniformly spaced or non-uniformly spaced to receive the fused plastic material forming the over-molding, thereby forming secure connection between end portion of the microchannel <NUM> and the tank holder <NUM> over-molded on the microchannel <NUM>. However, the present invention is not limited to any particular configuration, number and placement of the corrugations <NUM> formed on periphery of extreme ends of the microchannel tube <NUM> as long as the corrugations <NUM> ensure proper gripping connection between the microchannel tube <NUM> and the tank-holder <NUM> over-molded over the microchannel tube <NUM>.

In case of the battery cooler <NUM>, wherein the microchannel tubes <NUM> are disposed adjacent to each other in the second direction Z, particularly, the co-planar spaced microchannel tubes separated by a connection portion <NUM>, the connection portion <NUM> is formed with at least one opening 14a. Generally, the connection portion <NUM> extends throughout the length of the microchannel tubes <NUM>. Such configuration confers u-flow between the microchannel tubes <NUM> are disposed adjacent to each other in the second direction Z. In accordance with another embodiment, the connection portion <NUM> extends along a portion of entire length of the micro-channel tubes <NUM>. Preferably, the connection portion <NUM> extends end portions of the micro-channels, particularly, along portions 10b of the microchannel tubes <NUM> without powder coating. The opening 14a facilitate over-molding of the tank-holder <NUM> over the corresponding microchannel tubes <NUM>. More specifically, the at least one opening 14a is provided at the center of the connection portion <NUM> and facilitates uniform distribution of the fused plastic material on both sides of the microchannel tubes <NUM> during the over-molding of the tank holder <NUM> over the end portions of the micro-channel tubes <NUM>. Such configuration of the at least one opening 14a configures the tank holder <NUM> on both sides of the microchannel tubes <NUM>, thereby configuring secure connection between the microchannel tubes <NUM> and the tank <NUM>. However, the present invention is not limited to any particular configuration of the connection portion <NUM> and configuration, number and placement of the at least one opening 14a formed on the connection portion <NUM> as far as the at least one opening 14a ensures improved over-molding of the tank holder <NUM> on both sides of the microchannel tube <NUM>. Improved over-molding of the tank holder <NUM> over the end portions of the micro-channel tubes <NUM> leads to secure connection between the end portions of the micro-channel tubes <NUM> and the tank holders <NUM>. <FIG> illustrates an isometric view of the tank holder <NUM> that is secured to the end portions of the microchannel tube <NUM> by over-molding. Although, the tank holder <NUM> is depicted as a separate element, however, the tank holder <NUM> is securely formed on the end portions of the microchannel tubes by over-molding. The tank holder <NUM> includes a cavity formed thereon for securing the sealing gasket <NUM> by over-molding the sealing gasket <NUM> over the tank holder <NUM>.

Further, the tank <NUM> is securely mounted over the tank holder <NUM> by using mechanical connections such as for example, latching elements <NUM>. Generally, the tank <NUM> includes at least one peripheral wall <NUM>, the inlet 32a, the outlet 32b and a connecting opening <NUM>. The at least one peripheral wall <NUM> define an enclosure. The inlet 32a and the outlet 32b is for ingress and egress of the coolant with respect to the enclosure <NUM>. The connecting opening <NUM> is defined by the peripheral wall <NUM>. The connection opening <NUM> receives and holds at least one corresponding the microchannel tube <NUM> to configure fluid communication between the enclosure and the microchannel tube <NUM>. The mechanical connections for securely mounting the tank <NUM> over the tank holder <NUM> includes complementary snap engagement elements formed on the tank holder <NUM> and the tank <NUM> respectively. Particularly, the tank <NUM> includes a plurality of latching element <NUM> formed along the length thereof that are received in and engage with corresponding complementary loops and / or cavities <NUM> formed on the tank holder <NUM> to securely mount the tank <NUM> to the tank holder <NUM>. In accordance with one embodiment, the loops and / or cavities <NUM> are formed on different planar surfaces of the tank holder <NUM> to receive the corresponding latching elements <NUM>. In one embodiment, the two planar surfaces on which the loops and / or cavities <NUM> are formed are orthogonal with respect to each other. The loops and / or cavities <NUM> formed on a first planar surface of the tank holder <NUM> secures the tank <NUM> with respect to the tank holder <NUM> in a first direction whereas the loops and/ or cavities <NUM> formed on a second planer surface of the tank holder <NUM> secures the tank <NUM> with respect to the tank holder <NUM> in a second direction. Alternatively, the latching elements are formed on the tank holder <NUM> and are received in the corresponding complementary loops and /or cavities formed on the tank <NUM>. However, the present invention is not limited to the configuration of the latching elements and the complementary loops and / or cavities, whether formed on the tank holder <NUM> or the tank <NUM>, the number and placement of the latching elements <NUM> and the complementary loops as far as these ensure secure mounting of the tank <NUM> over the tank holder <NUM>. In accordance with an embodiment of the present invention, the peripheral wall <NUM> extends beyond the connecting opening <NUM> to cover the extreme ends of the microchannel tubes <NUM>, the portion 32a of the peripheral wall <NUM> extending beyond the connecting opening <NUM> is referred to as extension portion 32a. The extension portion further prevents any intrusion into the tank <NUM>.

Also, provision is provided to configure sealing between the microchannel tube <NUM> and the corresponding tank <NUM>. Generally, at least one sealing gasket <NUM> as illustrated in <FIG> is disposed between the microchannel tubes <NUM> and the tank <NUM> to ensure leak-proof and air tight connection between the microchannel tubes <NUM> and the tank <NUM>, thereby preventing leakage of the coolant and ensuring efficient performance of the battery cooler. The sealing gasket <NUM> is secured to at least one of the microchannel tube <NUM> and the tank holder <NUM>. The tank holder <NUM> is over-molded over the at least one extreme end of the microchannel tube <NUM>. Although, the description and the drawings disclose and depict only one sealing gasket <NUM>, however, multiple sealing gaskets <NUM> can be disposed between the microchannel tubes <NUM> and the tank <NUM> to ensure leak-proof and air tight connection between the microchannel tubes <NUM> and the tank <NUM>. In accordance with an embodiment of the present invention, the sealing gasket <NUM> takes the form of the cavity configured on the tank holder <NUM> formed by over molding and is pinched in the middle as illustrated in <FIG>. More specifically, the sealing gasket <NUM> is secured to extreme end of at least one of microchannel tube <NUM> by over-molding. The sealing gasket <NUM> is of resilient material, particularly, Ethylene Propylene Diene Monomer (EPDM) material and gets compressed as the tank <NUM> is securely mounted on the tank holder <NUM>. At least one of the tank holder <NUM> and the sealing gasket <NUM> are disposed between the microchannel tube <NUM> and the tank <NUM>. More specifically, at least one of the tank holder <NUM> and the sealing gasket <NUM> is coaxially received with respect to the microchannel tubes <NUM>. The sealing gasket <NUM> is secured to at least one extreme end of at least one of microchannel tube <NUM> by at least one of press-fitting or over-molding. Preferably, the sealing gasket <NUM> is over-molded over the tank holder <NUM>. Alternatively, the sealing gasket <NUM> is press fitted inside the groove <NUM> formed on the tank holder <NUM>. Further, at least one of the sealing gasket <NUM> and the tank holder <NUM> includes retainer elements such as for example opening and notches to retain the sealing gasket <NUM> with respect to the tank holder <NUM> connected by over-molding or any other way. In a preferred embodiment, both the tank holder <NUM> and the sealing gasket <NUM> formed by over-molding are disposed between the microchannel tube <NUM> and the tank <NUM>. In one embodiment of the present invention, the tank holder <NUM> includes at least one groove <NUM> formed thereon to receive and securely hold the sealing gasket <NUM> therein.

Generally, at least one of the microchannel tubes <NUM> is coated with powder coating of thermally conductive and electrically insulated material, except at the end portions thereof. The coating of thermally conductive but electrically insulated material permits heat transfer from the batteries "B" to the coolant flowing through the microchannel tubes <NUM> while sill preventing electric current from flowing from the batteries "B" to the coolant through the microchannel tubes <NUM>, thereby ensuring safety and short circuiting. The tank holder <NUM> over-molded over the end portions of the microchannel tubes <NUM> covers the interface between portions 10b and 10c of the microchannel tube <NUM> without the powder coating and with powder coating respectively, thereby preventing any chances of short-circuiting due to any gaps.

Also, is disclosed a method <NUM> of assembling a battery cooler <NUM> in accordance with an embodiment of the present invention. <FIG> illustrates a block diagram depicting the various steps of the method <NUM> for assembling the battery cooler <NUM>, particularly, the method <NUM> involves over-moulding for forming and securely mounting a tank holder <NUM> to at least one extreme ends of the microchannel tube <NUM>. Although, the various steps of the method <NUM> are depicted by blocks in the flow diagram and any number of steps described as method blocks can be combined in any order or can be performed in parallel to employ the method <NUM>, or an alternative method. Additionally, individual blocks may be deleted from the flow chart depicting the method without departing from the scope and ambit of the present invention. The method <NUM> is to be understood with reference to the following description along with the <FIG>.

The method <NUM> for assembling the battery cooler <NUM> includes the step <NUM> of powder coating at least a portion of at least one microchannel tube <NUM> with thermally conductive and electrically insulated material. Thereafter, the method <NUM> includes the step <NUM> of over-molding the tank holder <NUM> over at least one extreme end of the microchannel tube <NUM> such that the tank holder <NUM> covers interface between portions 10b and 10c of microchannel tube <NUM> without coating and with coating. The method <NUM> further includes the step <NUM> of securely mounting a sealing gasket <NUM> over at least one of tank holder <NUM> and the microchannel tube <NUM>, wherein mounting includes over-molding of the sealing gasket <NUM> over at least one of tank holder <NUM> and the microchannel tube <NUM>. Finally, the method includes the step <NUM> of securely mounting a tank <NUM> over the corresponding tank holder <NUM>. The step <NUM> of securely mounting the tank <NUM> over the corresponding tank holder <NUM> involves snap engagement between the tank <NUM> and the tank holder <NUM> using latching elements <NUM> formed on the tank <NUM> and the corresponding complementary loops formed on the tank holder <NUM>. Preferably, the sealing gasket <NUM> is over-molded over the extreme end of the microchannel tube <NUM>. However, present invention is not limited to any particular way of securely mounting the sealing gasket <NUM> over the microchannel tube <NUM>.

Claim 1:
A battery cooler (<NUM>) comprising:
• microchannel tubes (<NUM>) comprising respective multiple channels (10a) formed by extrusion;
• a tank holder (<NUM>) secured to the microchannel tube (<NUM>);
• a tank (<NUM>) securely mounted over the tank holder (<NUM>), wherein the tank (<NUM>) is secured to the tank-holder (<NUM>) by mechanical connections, and
• a sealing gasket (<NUM>) secured to at least one of the microchannel tube (<NUM>) and the tank holder (<NUM>),
characterized in that the tank holder (<NUM>) is over-molded over the at least one extreme end of the microchannel tube (<NUM>) and wherein the microchannel tubes (<NUM>) disposed adjacent to each other in a direction "Z" along a plane thereof are separated by a connection portion (<NUM>) formed with at least one opening (14a) to facilitate over-molding of the tank-holder (<NUM>) over the corresponding microchannel tube (<NUM>).