Battery Cooler Mechanical Assembly Eliminates Brazing
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Solution Overview
Problem
Brazing techniques used in battery coolers degrade the mechanical strength and straightness/flatness of tubes, leading to inefficient heat transfer and increased production costs.
Innovation Solution
A mechanically assembled cooler with seals between ducts, collectors, and covers, eliminating the need for brazing and ensuring fluid-tight connections without degrading mechanical strength or tube flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing is used to assemble cooler elements, then fluid-tight connections are achieved, but mechanical strength and tube straightness/flatness are degraded
Solution Approach 1:
The patent replaces the thermal joining process (brazing) with a mechanical assembly system consisting of collectors, covers, and sealing elements. The mechanical assembly uses compression seals and fluid pressure to achieve both connection and sealing, eliminating the need for high-temperature brazing that degrades tube properties.
Solution Approach 2:
The patent introduces sealing elements (such as O-rings or compression seals) as intermediaries between the collectors, covers, and tubes. These seals provide the fluid-tight connection traditionally achieved by brazing, while allowing the tube mechanical properties to remain intact.
2Reliability
If brazing is used to assemble cooler elements, then fluid-tight connections are achieved, but production costs increase
Solution Approach 1:
The patent replaces the expensive brazing process with a mechanical assembly system that uses standard sealing components. This substitution eliminates the need for specialized brazing equipment and high-temperature furnaces, thereby reducing production costs while maintaining sealing reliability.
Solution Approach 2:
The patent changes the assembly parameters from high-temperature thermal processes to room-temperature mechanical operations. This parameter change allows for simpler manufacturing equipment and lower production costs while achieving the same fluid-tight connection reliability.
3Manufacturing precision
If tube supports are increased during brazing to prevent defects, then tube straightness is improved, but chassis costs and production costs increase
Solution Approach 1:
The patent eliminates the need for tube supports during assembly by replacing brazing with a mechanical system. The collectors and covers are designed to accommodate tube positioning and sealing without requiring additional support structures, thereby reducing chassis complexity and production costs while maintaining tube straightness.
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
Enhances the mechanical strength and heat transfer efficiency of the cooler, reducing production costs and preventing leaks, while maintaining optimal temperature regulation for batteries.
Implementation Method 1
The mechanical connection and the seal between each collector and the ducts of the cooler are obtained via compression of a seal between these two components.
Implementation Method 2
A cooling fluid can then circulate through the tubes and the manifolds in order to exchange heat with the batteries.
Implementation Method 3
A cooling fluid can then circulate through the tubes and the manifolds in order to exchange heat with the batteries.
Data Source
AI summary
A cooler for at least one electrical energy storage element, the cooler comprising at least one heat-transfer liquid circulation duct, the ends of which penetrate into manifolds. Each of the manifolds comprises a collector having at least one opening for introduction and passage of at least one duct, and a cover covering the collector in such a way as to define a volume, into which the at least one duct opens, for circulation of the heat-transfer liquid. The at least one duct and the cover are mechanically assembled with the collector. A manifold further comprises at least one seal disposed between the collector and the at least one duct, and also between the collector and the cover.