Cylindrical cell liquid cooling coiled pipe processing and manufacturing process

Abstract

The invention discloses a cylindrical cell liquid cooling coiled pipe processing and manufacturing process, which removes a plurality of complex processes such as polishing, laser cleaning, acid pickling, powder spraying after drying, baking and the like, and directly completes the main processing process of a coiled pipe through key processes such as film pasting, bending, bonding of an injection joint and the coiled pipe by using glue and the like. The whole processing and manufacturing process is greatly shortened, and the production efficiency is remarkably improved; a complex machining joint is replaced by an injection molding joint, so that the machining cost is reduced; a high-performance adhesive is adopted to replace a welding process, so that the expenses of welding equipment, welding materials and the like are reduced, and the manufacturing cost and the BOM cost are also greatly reduced; pickling sewage, powder spraying pollution and welding harmful gas emission are avoided, multi-pass baking energy consumption is reduced, and the requirements for environmental protection, energy conservation and emission reduction are met; a film pasting process improves the insulation and voltage resistance qualified rate, and the stable and reliable quality of the coiled pipe is ensured through accurate process control and advanced detection means; the process is simple in step and convenient to operate, and construction convenience is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing three-electric thermal management components, and in particular to a process for processing and manufacturing a liquid-cooling serpentine tube for a cylindrical battery cell. Background Art

[0002] In fields such as new energy vehicles and energy storage devices, efficient heat dissipation of cylindrical battery cells is crucial, and liquid-cooled coils are widely used as key heat dissipation components. In the manufacture of three-electro-thermal management components, the traditional manufacturing process for liquid-cooled coils for cylindrical battery cells includes coil grinding, bending, high-frequency welding, laser cleaning, helium testing, pickling, insulation powder coating, and insulation withstand voltage testing. After drying, powder coating, and baking, the grinding, laser cleaning, pickling, and insulation powder coating processes are used to achieve insulation withstand voltage.

[0003] The manufacturing process has the following problems: (1) A large amount of wastewater is generated in the pickling process and other steps. Direct discharge without proper treatment will cause serious pollution to the environment; (2) The multiple baking procedures significantly increase energy consumption, which not only increases production costs but also does not conform to the development trend of energy conservation and emission reduction; (3) The powder spraying process cannot guarantee the uniformity of film thickness and the surface adhesion of particles causes insulation breakdown; (4) The cost of machined joint welding is high, and the complex process makes the entire manufacturing process lengthy, which increases the manufacturing cost and BOM (bill of materials) cost. Summary of the Invention

[0004] In order to solve the technical problems existing in the background technology, the present invention proposes a processing and manufacturing process for a liquid-cooling serpentine tube of a cylindrical battery cell.

[0005] The present invention proposes a manufacturing process for a cylindrical battery core liquid-cooling serpentine tube, comprising the following steps:

[0006] S1, Coil tube film application: In a dust-free environment, the protective film is evenly applied to the surface of the coil tube using high-precision film application equipment;

[0007] S2, bending: CNC bending equipment is used to control the bending angle and curvature according to the designed size and shape of the serpentine tube;

[0008] S3, joint bonding: Use glue dispensing equipment to perform quantitative glue injection on the serpentine tube and the injection-molded joint in an annular manner, and heat and cure the bonding area;

[0009] S4, helium test: Place the bonded serpentine tube in the sealed test chamber of the helium mass spectrometer leak detector, close the chamber door and test it. Determine whether the serpentine tube is leaking based on the test results.

[0010] S5, insulation and voltage withstand test: Connect the helium-tested serpentine tube to the test fixture of the insulation and voltage withstand test equipment to test the insulation performance and voltage withstand conditions.

[0011] Preferably, in step S1, the protective film is an insulating voltage-resistant film.

[0012] Preferably, the injection-molded joint is embedded with a metal skeleton.

[0013] Preferably, in step S3, before the injection molded joint is bonded, a cleaning step is also included: the serpentine pipe joint portion to be bonded and the bonding portion of the injection molded joint are placed on a clean workbench, and oil, dust and other impurities on the surface are removed using a detergent and a cleaning tool, and then wiped dry with a dry dust-free cloth.

[0014] Preferably, in step S4, helium of a certain pressure is filled into the detection chamber through a helium filling device, and then a helium mass spectrometer leak detector is started to detect the helium concentration in the detection chamber. According to the detection results, it is determined whether there is a leak in the serpentine tube. If a leak is detected, the leak location is marked. After the leak location is repaired, step S4 is repeated until the sealing performance of the serpentine tube meets the requirements.

[0015] Preferably, in step S5, the insulation and voltage resistance testing device is started to apply a set voltage to the serpentine tube for testing. During the testing process, the insulation and voltage resistance testing device monitors the insulation performance and voltage resistance of the serpentine tube in real time.

[0016] In summary, the present invention has the following beneficial effects: (1) The process is shortened to reduce manufacturing costs such as equipment use, labor and energy consumption; film pasting replaces powder spraying, reducing material and processing costs, and both manufacturing costs and BOM costs are reduced; (2) It avoids pickling wastewater, powder spraying pollution and welding harmful gas emissions, reduces multi-pass baking energy consumption, and meets environmental protection and energy conservation and emission reduction requirements; (3) film pasting improves the qualified rate, precise process control and advanced detection means ensure the stable and reliable quality of the serpentine tube, improves the product qualified rate, and reduces the defective scrap rate; (4) The process steps are simple and easy to operate. The film pasting and joint bonding process has low technical requirements for operators, reduces equipment maintenance and debugging time, and improves construction convenience; (5) Joint bonding replaces machined joints and high-frequency welding, reducing machining costs.

[0017] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic structural diagram of a serpentine tube and a plastic structure according to an embodiment of the present invention;

[0019] Figure 2 for Figure 1 Enlarged view of point A in the middle;

[0020] Figure 3This is a flow chart of the manufacturing process of the cylindrical battery cell liquid-cooling serpentine tube according to an embodiment of the present invention.

[0021] In the picture:

[0022] 1. Serpentine tube; 2. Injection molded joint; 3. Glue; 4. Insulation and voltage-resistant film; 5. Metal frame. DETAILED DESCRIPTION

[0023] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar symbols throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention, and are not to be construed as limiting the present invention.

[0024] like Figure 1-3 As shown, the present embodiment proposes a manufacturing process for a cylindrical battery cell liquid-cooling serpentine tube, comprising the following steps:

[0025] S1, Coil tube film application: In a dust-free environment, a high-precision film application device is used to evenly apply the protective film to the surface of the coil tube 1.

[0026] S2, bending: using CNC bending equipment to control the bending angle and curvature according to the design size and shape of the serpentine tube 1;

[0027] S3, joint bonding: Use a dispensing device to perform a circular quantitative injection of glue 3 on the serpentine tube 1 and the injection-molded joint 2, and heat and cure the bonding area;

[0028] S4, helium test: Place the bonded serpentine tube 1 in a sealed test chamber of a helium mass spectrometer leak detector, close the chamber door and perform a test to determine whether the serpentine tube 1 is leaking based on the test results;

[0029] S5, insulation and voltage withstand test: connect the serpentine tube 1 that has passed the helium test to the test fixture of the insulation and voltage withstand test equipment to test the insulation performance and voltage withstand condition.

[0030] In this way, the process uses film to achieve the insulation and voltage resistance of the serpentine tube. The film-sticking process replaces the grinding, laser cleaning, pickling, and insulation powder spraying processes in the original process, with a high pass rate and reduced costs. It solves the problem that a large amount of sewage will be generated in the pickling process and other links, and direct discharge without proper treatment will cause serious pollution to the environment. The baking process greatly increases energy consumption, which not only increases production costs, but also does not conform to the development trend of energy conservation and emission reduction. At the same time, injection molding joint bonding is used instead of machining, which greatly reduces processing costs.

[0031] Furthermore, in step S1, the protective film is provided as an insulating and voltage-resistant film 4. It should be noted that the insulating and voltage-resistant film 4 exhibits excellent flexibility, temperature resistance, and adhesion. The protective film serves, on the one hand, to protect the surface of the serpentine tube 1 from damage such as scratches and oxidation during subsequent processing; on the other hand, it can replace some processing steps in traditional processes in certain processes, reducing the generation of pollutants. For example, the protective film can, to a certain extent, resist the impact of tiny particles during processing, preventing defects such as pitting on the surface of the serpentine tube 1, thus eliminating the need for complex polishing.

[0032] Furthermore, in step S2, the CNC bending equipment is equipped with high-precision sensors and control systems, capable of real-time monitoring of parameters such as pressure and displacement during the bending process. Based on this feedback, the bending parameters are automatically adjusted to ensure dimensional accuracy and shape consistency after the serpentine tube is bent. Compared to traditional bending processes, the CNC bending equipment of the present invention offers a higher degree of automation and precision control, reducing errors caused by manual intervention while improving production efficiency.

[0033] like Figure 2 As shown, in step S3, the injection molded joint 2 is embedded with a metal skeleton 5. Specifically, the injection molded joint adopts high-performance engineering plastics, such as polyetheretherketone (PEEK), etc., which has the advantages of light weight, high strength, chemical corrosion resistance and high temperature resistance. The metal skeleton 5 adopts a lightweight and high-strength metal material, such as titanium alloy or carbon fiber reinforced composite material, etc., and the metal skeleton is embedded in the injection molded joint 2 through a special molding process, which not only enhances the overall strength and rigidity of the joint, but also ensures the lightweight of the joint. The internal structure of the injection molded joint 2 is optimized according to the connection method with the serpentine tube 1. For example, a special groove or protrusion structure is set on the inner wall of the injection molded joint 2 to increase the connection area and friction with the serpentine tube 1 to ensure the firmness of the connection.

[0034] Furthermore, in step S3, before the injection-molded joint 2 is bonded, a cleaning step is also included: the joint portion of the serpentine tube 1 to be bonded and the bonding portion of the injection-molded joint 2 to be bonded are placed on a clean workbench, and oil, dust, and other impurities on the surface are removed using a detergent and cleaning tools, and then wiped dry with a dry, dust-free cloth to ensure the bonding effect. Then, glue 3 is evenly applied to the joint portion using a precise dispensing device. After the application is completed, the injection-molded joint 2 is quickly and precisely docked with the end of the serpentine tube 1, and a dedicated fixture is used to apply a certain amount of pressure so that the glue 3 fully fills the joint gap.

[0035] Furthermore, in step S3, the bonding area is cured by placing the joined serpentine tubes 1 under a specific temperature and humidity environment (the specific values ​​of which are determined according to actual conditions, such as 25°C ± 2°C and 40% ± 5%). The adhesive 3 is then allowed to cure rapidly within a specified time (e.g., 30 minutes) to form a secure connection. Compared to traditional high-frequency welding processes, this not only reduces product weight but also significantly reduces machining costs. It also avoids high-temperature deformation, welding defects, and energy consumption that can occur during welding, and it produces no welding waste or harmful gases.

[0036] In this embodiment, in step S4, helium is filled into the detection chamber at a certain pressure (e.g., 0.5 MPa) by a helium filling device and maintained for a certain time (e.g., 5 minutes) to allow the helium to fully penetrate into the possible small leakage sites. Then, a helium mass spectrometer leak detector is started to detect the helium concentration in the detection chamber. Based on the detection results, it is determined whether the serpentine tube 1 has a leak. The detection accuracy of the helium mass spectrometer leak detector can reach 1×10 -9 Pa·m 3 / s or less, and can quickly and accurately determine if the coil is leaking. When the helium concentration exceeds a set threshold, the device automatically issues an alarm and marks the leak location. The operator can then repair the leak and repeat step S4 until the coil's sealing performance meets design requirements. This rigorous helium inspection process ensures that the liquid-cooled coil will not leak coolant during use, ensuring the heat dissipation and safety of the cylindrical battery cells.

[0037] It should be noted that the helium mass spectrometer leak detector can accurately detect whether there are even tiny leaks in the coiled tube, with detection accuracy reaching industry-leading levels. By optimizing detection parameters such as helium pressure and detection time, the sealing performance of the coiled tube 1 can be quickly and accurately determined, ensuring product quality.

[0038] In step S5, the insulation and voltage resistance testing equipment is started, and a set voltage is applied to the serpentine tube for testing. During the testing process, the insulation and voltage resistance testing equipment monitors the insulation performance and voltage resistance of the serpentine tube in real time. If it is detected that the insulation and voltage resistance performance of the serpentine tube does not meet the requirements, the equipment automatically issues an alarm and records the relevant data. The unqualified serpentine tube is analyzed and processed, such as checking whether there are problems such as damage to the insulation layer and poor connection of the joints. After repair, it is retested until it is qualified. The insulation and voltage resistance testing process ensures the safety and reliability of the liquid-cooled serpentine tube in the electrical environment, and prevents faults such as short circuits caused by insulation performance problems.

[0039] In summary, compared to traditional processes, the manufacturing process for the cylindrical battery cell liquid-cooled serpentine tube in this embodiment eliminates multiple complex steps, such as grinding, laser cleaning, pickling, drying, powder coating, and baking. Instead, the main processing steps of the serpentine tube are completed directly through key processes such as film lamination, bending, and gluing the injection-molded connector to the serpentine tube. This significantly shortens the entire manufacturing process and significantly improves production efficiency. Due to the use of new processes and materials, complex machined connectors are replaced with injection-molded plastic, reducing machining costs. Furthermore, high-performance adhesives are used instead of welding processes, reducing the costs of welding equipment and materials, resulting in a significant reduction in bill of materials (BOM) costs. Practical verification has shown that both manufacturing and BOM costs have decreased by over 20%. The process steps are relatively simple, making it more convenient to operate. For example, the film lamination process requires only a simple lamination operation on specific equipment, and the connector bonding process does not require complex welding equipment or skills, lowering the technical requirements for operators. This also reduces equipment maintenance and commissioning time, improving construction convenience. This also avoids problems like large amounts of wastewater generated by pickling and harmful gases from welding. Throughout the entire process, pollutants are minimal, aligning with modern environmental protection concepts and contributing to green production. Furthermore, energy-intensive processes like multiple baking steps and high-frequency welding are eliminated, significantly reducing energy consumption. Furthermore, the new equipment and processes employed also boast high energy efficiency during operation, further achieving the goal of low energy consumption.

[0040] It should be noted that the high-precision film-laminating equipment, high-precision film-laminating equipment, dispensing equipment, helium mass spectrometer leak detector, insulation and voltage resistance testing equipment, cleaning agents and cleaning tools, dust-free cloth, etc. in this embodiment can all refer to the existing technology, and this article will not repeat them.

[0041] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as limiting the present invention.

[0042] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0043] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A process for manufacturing a cylindrical battery cell liquid cooling serpentine tube, characterized in that: The following steps are involved: S1, Coil tube film application: In a dust-free environment, the protective film is evenly applied to the surface of the coil tube using high-precision film application equipment; S2, bending: CNC bending equipment is used to control the bending angle and curvature according to the designed size and shape of the serpentine tube; S3, joint bonding: Use glue dispensing equipment to perform quantitative glue injection on the serpentine tube and the injection-molded joint in an annular manner, and heat and cure the bonding area; S4, helium test: Place the bonded serpentine tube in the sealed test chamber of the helium mass spectrometer leak detector, close the chamber door and test it. Determine whether the serpentine tube is leaking based on the test results. S5, insulation and voltage withstand test: Connect the helium-tested serpentine tube to the test fixture of the insulation and voltage withstand test equipment to test the insulation performance and voltage withstand conditions.

2. The manufacturing process of the cylindrical battery core liquid cooling serpentine tube according to claim 1, characterized in that: In the step S1, the protective film is set as an insulating voltage-resistant film.

3. The manufacturing process of the cylindrical battery core liquid cooling serpentine tube according to claim 1, characterized in that: In step S3, a metal skeleton is embedded in the injection-molded joint.

4. The manufacturing process of the cylindrical battery core liquid cooling serpentine tube according to claim 3, characterized in that: In the step S3, before the injection molded joint is bonded, a cleaning step is also included: the serpentine pipe joint portion to be bonded and the bonding portion of the injection molded joint are placed on a clean workbench, and oil, dust and other impurities on the surface are removed using a detergent and a cleaning tool, and then wiped dry with a dry dust-free cloth.

5. The manufacturing process of the cylindrical battery core liquid cooling serpentine tube according to claim 1, characterized in that: In step S4, helium of a certain pressure is filled into the detection chamber by a helium filling device, and then a helium mass spectrometer leak detector is started to detect the helium concentration in the detection chamber. Based on the detection results, it is determined whether there is a leak in the serpentine tube. If a leak is detected, the leak location is marked. After the leak location is repaired, step S4 is repeated until the sealing performance of the serpentine tube meets the requirements.

6. The manufacturing process of the cylindrical battery core liquid cooling serpentine tube according to claim 1, characterized in that: In step S5, the insulation and voltage resistance testing device is started to apply a set voltage to the serpentine tube for testing. During the testing process, the insulation and voltage resistance testing device monitors the insulation performance and voltage resistance of the serpentine tube in real time.

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