Full-Surface Adhesive Bonding for Cooling Plate and Structural Component
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Solution Overview
Problem
Conventional production processes for composite cooling plates and structural components in electrical vehicle batteries face limitations due to the need for identical materials, mechanical weakening from heat-induced processes, and challenges in achieving reliable adhesive bonding with consistent adhesive application, leading to potential air inclusions and reduced thermal coupling.
Innovation Solution
A process utilizing full-surface adhesive bonding between the cooling plate and structural component, allowing for the use of non-weldable and non-solderable materials, with precise adhesive application to ensure reliable fixing and thermal coupling, using adhesives like epoxy resin, polyurethane, or polyolefin to manage thermal expansion and reduce energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to bond the cooling plate and structural component, then a dependable bond is achieved, but the materials must be identical or similar and the materials are mechanically weakened by heat
Solution Approach 1:
An adhesive layer is introduced as an intermediary substance between the cooling plate and structural component, enabling bonding between dissimilar materials without direct thermal or mechanical contact requirements. The adhesive serves as a mediator that transfers both mechanical loads and thermal energy between the two components while accommodating different material properties.
Solution Approach 2:
The bonding method transitions from high-temperature processes (soldering/welding) to lower-temperature adhesive bonding, changing the thermal parameter of the bonding process. This allows dissimilar materials to be bonded without the restrictions of material compatibility required for welding, while also preserving the mechanical properties of the base materials.
2Reliability
If welding or soldering is used, then a dependable bond is achieved, but heat is introduced that mechanically weakens the materials and increases energy costs
Solution Approach 1:
The adhesive acts as a thermal and mechanical intermediary that enables bonding at lower temperatures compared to welding or soldering. This reduces the energy input required for the bonding process while maintaining bond reliability through the adhesive's bonding mechanisms.
Solution Approach 2:
The adhesive is a consumable material that is applied in a controlled manner and cures to form the bond. While the adhesive itself is relatively inexpensive compared to the energy costs of welding, it provides a permanent bonding solution without requiring high energy input during application.
3Adaptability or versatility
If adhesive bonding is used, then material selection freedom is increased, but it is difficult to ensure sufficient and optimized adhesive quantity and avoid air inclusions
Solution Approach 1:
The adhesive is applied to one of the bonding surfaces before assembly, allowing for controlled distribution and optimization of adhesive quantity in advance. This preliminary application ensures adequate adhesive coverage while minimizing excess and preventing air inclusions through proper application techniques.
Solution Approach 2:
The adhesive application is optimized for the specific joint geometry and loading conditions, with adhesive quantity and distribution tailored to the local requirements of each bonding area. This ensures sufficient adhesive in critical areas while avoiding excess that could lead to defects.
4Adaptability or versatility
If adhesive bonding is used, then material selection freedom is increased, but the adhesive bond must meet stringent requirements for heat resistance, long-term stability, and solvent resistance
Solution Approach 1:
The adhesive selection and formulation are optimized for the specific thermal and chemical environment, with parameters such as glass transition temperature, crosslink density, and chemical composition adjusted to achieve the required heat resistance (up to 120°C), long-term stability at 80°C, and solvent resistance to water-Glysantin mixtures.
Solution Approach 2:
The adhesive system may incorporate composite formulations combining multiple polymers, fillers, and additives to achieve the required combination of thermal stability, mechanical properties, and chemical resistance. This composite approach allows tailoring the adhesive properties to meet the stringent requirements of the battery cooling application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables dependable bonding and effective thermal coupling between dissimilar materials, reduces energy costs, and minimizes mechanical stress, while avoiding defects and ensuring consistent adhesive application, thus enhancing the structural integrity and efficiency of the composite.
Implementation Method 1
the cooling plate and the structural component are in essence full-surface adhesive-bonded to one another by means of an adhesive
Implementation Method 2
heat can be absorbed from the structural component and transported away from the structural component
Data Source
AI summary
A process for producing a composite. The process may include providing a cooling plate through which a temperature-control fluid is flowable, providing a structural component that is coolable via the cooling plate, and fixing and thermal coupling the cooling plate and the structural component to one another via full-surface adhesive bonding the cooling plate and the structural component to one another. Full-surface adhesive bonding the cooling plate and the structural component to one another may include arranging an adhesive in a joint disposed between the cooling plate and the structural component.