Electric Car Battery Cooling Device Bonding Method
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Solution Overview
Problem
Conventional electric car battery cooling devices experience leakage due to poor bonding between the upper and lower cases, resulting from uncoated portions or pores in the flux layer, which leads to inefficient heat transfer and reduced battery performance.
Innovation Solution
A method involving the application of a fluoride-based aluminum flux, mixed with water and a binder, in two stages, followed by drying and thermal bonding, to ensure a dense bonding structure between the clad plate cases, preventing leaks and enhancing bonding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a flux is applied once to bond the upper case and lower case, then the bonding process is simple and fast, but uncoated portions or pores are generated resulting in leakage
Solution Approach 1:
The flux is applied to the bonding surfaces before the thermal bonding process begins. This preliminary application ensures that the flux is already in position to remove oxide layers and facilitate bonding when heating occurs, preventing uncoated portions that would cause leakage.
Solution Approach 2:
The flux composition is specifically formulated with fluoride-based aluminum flux mixed with water and binder in controlled proportions (15-40 wt% aluminum flux, 55-85 wt% water, 0-5 wt% binder). These parameter changes in composition and application thickness (30-50 μm) ensure complete coverage and dense bonding structure.
2Manufacturing precision
If the flux layer is made thicker to cover all surfaces, then coating coverage is improved, but the structure becomes less dense and more prone to pores
Solution Approach 1:
The flux layer thickness is precisely controlled within the range of 30-50 μm. This optimized thickness parameter ensures sufficient coverage of the bonding surfaces while maintaining a dense structure that prevents pore formation. The specific composition ratios of flux components further ensure uniform distribution without excessive thickness.
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 achieves a dense bonding structure, preventing leaks and ensuring excellent bonding performance, as demonstrated by tests showing no defects in samples with two-time flux application, thereby maintaining efficient heat transfer and battery efficiency.
Implementation Method 1
The reason for using the flux is that the bonding is rarely achieved due to an oxide layer formed on the surface of the upper case 110 or the lower case 120. In order to remove the oxide layer, the flux is applied to the surface of the upper case 110 or the lower case 120 and the oxide layer formed on the surface can be removed while the flux is melted.
Implementation Method 2
a flux application step of applying a flux on bonding surfaces of the upper case and the lower case such that the flux is laminated on the upper adhesive layer and the lower adhesive layer; and a thermal bonding step of stacking and heating the upper case and the lower case such that applied flux layers are in contact with each other
Implementation Method 3
a thermal bonding step of stacking and heating the upper case and the lower case such that applied flux layers are in contact with each other
Data Source
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AI summary
The present invention relates to a method for manufacturing a device for cooling an electric car battery and, more particularly, to a method for manufacturing an electric car battery cooling device wherein a flux is applied to an upper case and a lower case, which constitute a cooling device, and the cases are then heated/bonded to each other, and, particularly, the cases are bonded to each other after applying the flux two times such that no leak occurs through the bonded part, thereby making it possible to secure an excellent bonding performance.