Battery Cooler Supply-Discharge Insert for Brazing-Free Assembly

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Solution Overview

Problem

The manufacturing process of coolers with a brazed supply-discharge portion is complicated due to the fixed cap configuration, making it difficult to assemble and integrate with electricity storage apparatuses efficiently.

Innovation Solution

A cooler design featuring a supply-discharge portion with an insertion portion and packing member, integrally formed by resin, which is easily assembled by insertion into the cooler main body and secured through engagement or contact with the apparatus, eliminating the need for brazing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the supply-discharge portion with a fixed cap is brazed to the cooler main body, then the connection strength is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The supply-discharge portion is divided into a separate insertable component with an insertion portion, distinct from the cooler main body. This segmentation allows the supply-discharge portion to be manufactured independently and then assembled into the cooler main body through insertion, eliminating the need for complex brazing operations while maintaining connection integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An insertion portion with packing members serves as an intermediary mechanism between the supply-discharge portion and the cooler main body. The packing members (first and second packing members) act as mediators to create sealing connections without requiring brazing, thus simplifying the manufacturing process while ensuring reliable fluid-tight connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the supply-discharge portion is brazed to the cooler main body, then the connection reliability is improved, but the ease of manufacture deteriorates

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The supply-discharge portion is segmented as a separate insertable component with an insertion portion that can be independently manufactured. This segmentation enables simpler manufacturing processes for each component while ensuring reliable connections through the insertion and packing mechanism, avoiding the complexity of brazing operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brazing process (thermal-chemical joining method) is replaced with a mechanical insertion system featuring an insertion portion and packing members. This mechanical substitution maintains connection reliability through proper sealing while dramatically improving ease of manufacture by eliminating specialized brazing equipment and processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the supply-discharge portion is inserted into the cooler main body, then the ease of manufacture is improved, but the positioning precision may deteriorate

Engineering Contradiction:

Improveease of manufactureVSAvoidpositioning precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The packing members (first packing member on the inner peripheral surface of the insertion portion, and second packing member in the cooler main body) serve as intermediaries that ensure precise positioning and sealing. These packing members are configured to contact specific surfaces, guaranteeing accurate positioning of the supply-discharge portion within the cooler main body while maintaining ease of assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insertion portion and cooler main body are designed with specific local features (grooves, contact surfaces, packing member positions) that ensure precise positioning at critical locations. This local quality approach ensures that the supply-discharge portion is accurately positioned where it contacts the cooler main body, maintaining manufacturing precision while simplifying the overall assembly process.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20260018700A1Cooler, arrangement structure of supply-discharge portion, and electricity storage apparatus

Publication Date: 2026.01.15 TOYOTA JIDOSHA KK

AI summary

A cooler mounted on an electricity storage apparatus includes: a cooler main body in which a circulation passage of a refrigerant is provided; and a supply-discharge portion that communicates with the circulation passage of the cooler main body and is to be inserted into the cooler main body to supply the refrigerant to the circulation passage of the cooler main body or discharge the refrigerant from the circulation passage of the cooler main body. The supply-discharge portion includes a contacting portion that arranges the supply-discharge portion in a preset position in the cooler main body by being in contact with a portion to be contacted of the electricity storage apparatus, in a state in which the cooler is mounted on the electricity storage apparatus.