Battery Cooler Tube-to-Tank Welding for Leak-Free Microchannel Joints
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Solution Overview
Problem
Conventional brazing processes for joining microchannel tubes to tank assemblies in battery coolers are inefficient, energy-intensive, environmentally harmful, and prone to coolant leakage due to gaps at the triple point interface, leading to inefficient cooling and reduced battery performance.
Innovation Solution
A laser welding process is used to join extruded tubes with thicker lateral walls to tank assemblies, filling gaps at the triple point interface and ensuring a secure, airtight connection, which can also include ribs or crimping tabs for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to join microchannel tubes to tank assembly, then connection is formed, but mechanical resistance of microchannel tubes deteriorates due to inherent heating
Solution Approach 1:
The patent segments the heating process by using individual heating elements positioned only at the joint regions where tubes connect to the tank assembly, rather than heating the entire tube length. This localized segmentation of thermal input preserves tube mechanical properties while achieving brazed connections.
Solution Approach 2:
The patent applies local quality by concentrating heating only at the specific joint locations where tubes meet the tank assembly, using individually controllable heating elements. This ensures adequate heat for brazing at connection points while avoiding unnecessary heating of the microchannel tubes that would compromise their mechanical resistance.
2Reliability
If entire microchannel tube is subjected to brazing in brazing furnace, then connection is formed, but energy is wasted and larger furnaces are required
Solution Approach 1:
The brazing process is segmented into discrete localized heating zones at each joint, rather than heating the entire tube. Individual heating elements are positioned only where connections are needed, enabling reliable brazing while minimizing energy consumption and eliminating the need for large furnaces.
Solution Approach 2:
The patent extracts the heating function from a large furnace environment and implements it through compact, localized heating elements positioned directly at the joint regions. This extraction eliminates the energy wastage associated with heating large furnace chambers while maintaining connection reliability.
3Strength
If brazing process is used, then connection is formed, but CO2 emissions occur that render working environment hazardous and cause environmental harm
Solution Approach 1:
The patent employs electric heating elements that consume electricity rather than combustible materials, eliminating CO2 emissions. These heating elements are simple, compact, and can be disposed of or replaced easily after use, providing strong connections without environmental harm.
4Reliability
If fillet joint welding or filler wire process is used to fill gap at triple point, then connection is formed, but joining process becomes slow and inconvenient
Solution Approach 1:
The patent incorporates gap-filling material directly into the joint design during the molding process, creating protrusions on the tube outer surface that automatically fill the triple point gap during assembly. This preliminary preparation eliminates the need for slow post-assembly filling operations, maintaining high productivity while ensuring reliable sealing.
5Strength
If conventional joining processes are used, then connection is formed, but gap at triple point leads to coolant leakage and insufficient coolant supply
Solution Approach 1:
The patent prepares the joint interface in advance by creating protrusions on the tube outer surface during molding. These protrusions are specifically designed to fill the triple point gap when the tube is inserted into the tank assembly, ensuring airtight sealing and preventing coolant leakage before the assembly is complete.
Solution Approach 2:
The patent applies local quality by creating localized protrusions only at the critical triple point regions where gaps would form. This targeted geometric modification ensures reliable sealing at the most vulnerable locations without requiring changes to the entire tube or tank assembly structure.
6Reliability
If thicker lateral walls are added to tube end portions, then gap filling and sealing are improved, but tube complexity increases
Solution Approach 1:
The patent incorporates the thicker lateral wall sections directly into the tube molding process, creating the sealing structures as integral parts of the tube during manufacturing. This preliminary formation of protrusions eliminates the need for separate sealing components or complex assembly steps, maintaining simplicity while improving reliability.
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 method provides a quick, efficient, and reliable connection that prevents coolant leakage, improving cooling efficiency and extending battery life by preventing overheating.
Implementation Method 1
A laser welding process is used to join extruded tubes with thicker lateral walls to tank assemblies
Implementation Method 2
filling gaps at the triple point interface and ensuring a secure, airtight connection
Data Source
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AI summary
A heat exchanger (100) includes a tank assembly (10) and a tube (20). The tank assembly (10) is formed by joining a pair of panels (10a) and (10b). The tube (20) includes a plurality of channels (22). The tube (20) is received and joined to the tank assembly (10). At least one of the extreme end portions of the tube (20) is having at least one of the lateral walls (20a) comparatively thicker than the longitudinal walls (20b) and channel walls (22a) of the tube (20).