Battery Cooler Crimped Casing Assembly for Leak-Proof Thermal Contact

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Solution Overview

Problem

Conventional battery thermal management systems face challenges with expensive and time-consuming assembly, stress concentration, and leakage issues due to screw connections, which affect heat dissipation and mechanical integrity.

Innovation Solution

A crimping connection mechanism using tabs, clips, or hooks on the thermal regulation device and ribs, slots, or profiled structures on the casing to create a robust, inexpensive, and secure connection between the battery cooler and casing, ensuring improved surface contact and leak-proof sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screw connection is used to connect battery cooler and casing, then connection strength is improved, but assembly time and cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces the screw connection mechanism with a snap-fit connection mechanism. The battery cooler includes protrusions that engage with corresponding recesses in the casing, eliminating the need for screws and holes. This mechanical substitution achieves both strong connection and rapid assembly without requiring drilling or fastening operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The battery cooler is segmented with integrated protrusions that function as both structural support and connection elements. The casing is segmented with corresponding recesses that receive the protrusions. This segmentation allows the connection function to be distributed across multiple engagement points, providing both strength and ease of assembly.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If screw holes are formed in battery cooler, then connection is achieved, but stress concentration and leakage occur

Engineering Contradiction:

Improveconnection capabilityVSAvoidmechanical integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent extracts the connection function from the battery cooler body by using protrusions that extend from the cooler's surface. This eliminates the need to form holes through the cooler, thereby removing the source of stress concentration and potential leakage paths while maintaining connection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating holes in the battery cooler for screw passage, the patent inverts the approach by having the cooler provide protruding connection elements that engage with recesses in the casing. This inversion eliminates the need for through-holes and maintains the integrity of the cooler structure.

Inventive Principle:

Principle #13The other way round (Inversion)

3Temperature

If surface contact between battery cooler and casing is improved, then heat dissipation is enhanced, but assembly complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the connection function and the thermal contact function into a single integrated structure. The protrusions on the battery cooler serve dual purposes: providing mechanical connection to the casing and ensuring large surface contact area for heat dissipation. This merging eliminates the need for separate alignment or positioning steps, reducing assembly complexity while improving thermal contact.

Inventive Principle:

Principle #5Merging (Combining)

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

The crimping connection provides a quick, secure, and leak-proof assembly that enhances heat dissipation, prevents mechanical failure, and maintains the integrity of the battery cooler, while being cost-effective and efficient.

Implementation Method 1

At least one of the thermal regulation device and the casing includes corresponding connection means that configure crimping connection between the thermal regulation device and the casing

Methodology Applied

Scientific EffectCrimping: Deformation

Implementation Method 2

The channel plate is disposed abutting the base plate and formed with channels to define fluid flow passages between the base plate and the channel plate

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

formed with channels to define fluid flow passages

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4481315A1A thermal management system

Publication Date: 2024.12.25 VALEO ELECTRIFICATION

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AI summary

A thermal management system (100) for electrical components generating heat during operation includes a thermal regulation device (10), a casing (20) and a sealing element (30). The thermal regulation device (10) cools the electrical components and includes a base plate (12) and a channel plate (14). The base plate (12) supports the electrical components thereon. The channel plate (14) abutting the base plate (12) is formed with channels (14b) to define fluid flow passages between the base plate (12) and the channel plate (14). The casing (20) at least partially encapsulates the electrical components supported on the thermal regulation device (10). The sealing element (30) is disposed between the thermal regulation device (10) and the casing (20). At least one of the thermal regulation device (10) and the casing (20) includes corresponding connection means that configure crimping connection between the thermal regulation device (10) and the casing (20).