Battery Pack Cooling Plate Assembly With Integrated Brazing
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Solution Overview
Problem
Conventional battery pack cases require numerous extrusion shapes, leading to a large number of extrusion dies and processing tools, a complex assembly process, excessive manufacturing time, high defect rates due to welding, and dimensional issues.
Innovation Solution
A cooling plate assembly for battery pack cases is manufactured using a multilayer aluminum material with integrated brazing, involving a middle plate, cooling plate, and collision reinforcements, which are bonded through continuous furnace brazing at specific atmospheric conditions, reducing the need for separate assembly and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate manufacturing and assembly methods are used for middle plate, cooling plate, and collision reinforcements, then each component can be manufactured independently, but the assembly process becomes very complicated and manufacturing cycle time becomes excessively long
Solution Approach 1:
The patent combines the middle plate, cooling plate, and collision reinforcements into a single integrated structure manufactured through one-shot press forming. This merging of previously separate components and manufacturing steps into a single operation dramatically reduces assembly time and complexity while maintaining the functional independence of each component through integrated design
2Adaptability or versatility
If numerous extrusion shapes are used for sub-parts, then functional requirements are met, but the number of extrusion dies and processing tools required becomes large
Solution Approach 1:
The patent creates a universal press-formed structure that integrates multiple functions (structural support, cooling, collision reinforcement) into a single component. This multi-functional design eliminates the need for multiple specialized extrusion dies and processing tools, as one press forming operation produces all required features
3Strength
If multiple separate components are assembled with lots of welding points, then structural stability is achieved, but the number of welding defects and dimensional dissatisfaction due to product deformation increases
Solution Approach 1:
The patent merges multiple components into a single press-formed piece, eliminating welding joints entirely. This integration maintains structural stability through the inherent strength of the press-formed structure while avoiding dimensional distortion and defects associated with multiple welding operations
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
This approach simplifies the assembly process, reduces manufacturing defects, and enhances structural stability by ensuring high bonding strength and rigidity, thereby lowering production costs and cycle times.
Implementation Method 1
the middle plate, the cooling plate, and the collision reinforcements are integrally braze-bonded
Implementation Method 2
integrally braze-bonded
Data Source
AI summary
A cooling plate assembly of a battery pack case includes a middle plate, a cooling plate bonded to a lower surface of the middle plate, and a plurality of collision reinforcements which are bonded to an upper surface of the middle plate and include a center member and a cross member, wherein the middle plate, the cooling plate, and the collision reinforcements are integrally braze-bonded. A structural stability of the battery pack case can be sufficiently secured, an assembly process can be dramatically simplified, and a manufacturing defective rate can also be innovatively reduced so that quality control can be very easily performed.