A non-metallic intercooler assembly includes an intake header tank, outlet
header tank, and a multitude of non-metallic charge tubes which
communicate airflow from the intake header tank to the outlet header
tank. Several combinations of plastics parts are described. Tanks of
intercoolers can be made from plastics today but with complicated
clamping and sealing. Each tank in this description can be laser welded
in place. Various combinations of laser opaque and laser transparent
materials are utilized to achieve an effective laser welding assembly
process. Intake systems for automotive use are widely made of plastic
materials today and this description shows how those types of materials
can be employed in an intercooler. Each non-metallic tube can be
supported by a plastic fin feature whose primary function is to support
the structure to promote airflow conditions favorable to heat transfer.