Battery Cooler Joint Surface Layout for Easier Brazing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing coolers for batteries require costly manufacturing processes due to the need for specialized holders or large welding facilities to join the cooling plate and lid bodies, as the vertical surfaces lead to brazing material loss and complex welding directions.
Innovation Solution
A cooler design with a cooling plate featuring partition walls and openings that allow for joint surfaces oriented towards the height direction, reducing the likelihood of brazing material loss and eliminating the need for specific welding directions, thus simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cooling plate and lid bodies are joined by brazing with vertical joint surfaces, then the structural integrity is improved, but the brazing material falls off and manufacturing cost increases
Solution Approach 1:
The patent changes the orientation of the joint surface from vertical to inclined, directing it toward the height direction rather than the longitudinal direction. This dimensional reorientation prevents brazing material from falling off while maintaining structural integrity, eliminating the need for holders and reducing manufacturing cost
2Strength
If the cooling plate and lid bodies are joined by welding, then the joint strength is improved, but large welding facilities are required and manufacturing cost increases
Solution Approach 1:
By orienting the joint surface toward the height direction rather than requiring horizontal-direction welding, the patent enables welding from a vertical direction using standard equipment, eliminating the need for large specialized welding facilities
3Reliability
If holders are used to prevent brazing material loss, then the brazing quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the need for holders by reorienting the joint surface to an inclined configuration facing the height direction, which naturally retains brazing material during the brazing process, maintaining quality while reducing manufacturing cost
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 design reduces manufacturing costs by minimizing brazing material loss and eliminating the need for complex welding setups, while maintaining effective coolant passage closure and pressure management.
Implementation Method 1
when the cooling plate portion and the lid portion are joined by brazing
Data Source
AI summary
A cooler has a coolant passage. The cooler includes a cooling plate portion having a plurality of partition walls extending in a longitudinal direction and partitioning the coolant passage in a width direction orthogonal to the longitudinal direction, and an opening that opens the coolant passage in a first longitudinal direction that is one direction of the longitudinal direction and a first height direction that is one direction of a height direction orthogonal to the longitudinal direction and the width direction; and a lid portion joined to the cooling plate portion so as to close the opening of the cooling plate portion. A joint surface of the cooling plate portion with the lid portion is directed further toward the first height direction side than toward the longitudinal direction.