Battery Cooling Plate Port Geometry for Strong Brazed Joints
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Solution Overview
Problem
Conventional heat transfer plates for battery cooling in electric vehicles face challenges in assembly, manufacturing, and ensuring a secure connection while maintaining thermal efficiency, leading to increased thermal loads and potential overheating issues.
Innovation Solution
A heat transfer plate design featuring a plate body formed from two record elements with a connecting socket that includes a connection section with elliptical or elliptical-shaped outer contours, optimized for soldering and integration, ensuring a high-strength, gap-friendly connection between the record elements and the connecting socket, which is aligned parallel to the plate elements, facilitating efficient cooling fluid flow and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional connecting pieces are formed or machined and connected to the plate body, then quick installation of cooling fluid lines is enabled, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The connecting piece is integrally formed with the plate body as a single component during the stamping process, eliminating separate assembly steps for attaching connecting pieces to the plate body while maintaining quick installation capability for cooling fluid lines
2Reliability
If connecting pieces are joined to the plate body using conventional methods, then connection is achieved, but manufacturing precision and connection reliability are compromised
Solution Approach 1:
The connecting piece is pre-formed with precise geometric features (recesses, protrusions, and guiding surfaces) during the stamping process that ensure accurate alignment and positioning before the final joining operation, thereby achieving both high manufacturing precision and connection reliability
3Ease of manufacture
If plate elements are joined with large gap tolerance, then manufacturing is easier, but thermal resistance increases and heat transfer efficiency decreases
Solution Approach 1:
The invention changes the gap parameter from a large tolerance range to a controlled narrow range (0.05-0.5mm) by implementing precise guiding surfaces and positioning features in the connecting piece, achieving both ease of manufacture through standardized stamping processes and low thermal resistance through controlled gap dimensions
4Strength
If connecting pieces are designed with complex geometry for secure connection, then connection strength is improved, but manufacturing cost and scrap rate increase
Solution Approach 1:
The connecting piece is segmented into distinct functional zones (guiding surfaces, positioning protrusions, recesses for plate element integration) that can be independently optimized during stamping, achieving strong connections through distributed contact areas while maintaining manufacturing efficiency and low scrap rates
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 solution provides a robust, efficient, and process-stable connection that reduces thermal resistance, enhances heat transfer, and minimizes scrap rates by optimizing the connection geometry and soldering process, ensuring reliable cooling performance.
Implementation Method 1
The plate elements are brazed together, integrating the connecting section of the connecting piece into the receiving section of the plate body
Implementation Method 2
A heat exchanger plate is used for a wide variety of applications. A heat exchanger plate of the type in question here is, in particular, a cooling plate for cooling motor vehicle batteries
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A cooling plate for battery cooling comprises a plate body (2) formed from two plate elements (3, 4) and a connection port (6) for a cooling fluid. The connection port (6) has a connection section (7) which is inserted into a receiving section (8) of the plate body (2) formed between the plate elements (3, 4). The connection section (7) has two arcuate wall sections (16, 17) in cross-section and two opposing, outwardly directed longitudinal ribs (9). The receiving section (8) has longitudinal grooves (10) extending in the region of the joining plane (FE) between the plate elements (3, 4). The longitudinal ribs (9) run within the longitudinal grooves (10).