Busbar Cooling Module With Insert-Molded Leak-Safe Pipe Coupling
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Solution Overview
Problem
Existing cooling systems for electric vehicles fail to provide efficient heat dissipation for high-heat batteries, leading to potential damage and increased product costs due to the need for additional members to prevent refrigerant leakage and complex structures.
Innovation Solution
A cooling module with a thermally conductive heat dissipation part and pipe part, coupled by insert-molding, which includes a heat dissipation body, pipe coupling portion, and busbar coupling portion, allowing for improved thermal conductivity and electrical insulation, reducing the number of components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water cooling is used to cool high-heat batteries, then cooling efficiency is improved, but additional members such as rubber rings are required to prevent leakage, increasing product cost and decreasing assembly property
Solution Approach 1:
The heat dissipation part and pipe part are merged into a single integrated component through insert-molding technology. The pipe part is inserted into the heat dissipation part during the molding process, creating a unified structure that eliminates the need for separate sealing components like rubber rings while maintaining effective sealing and cooling functionality.
Solution Approach 2:
The integrated heat dissipation part serves multiple functions simultaneously: it acts as both the cooling structure and the sealing barrier. The insert-molded pipe connection provides both structural support and leakage prevention, eliminating the need for dedicated sealing components and simplifying the overall assembly.
2Reliability
If additional members such as rubber rings are used to prevent refrigerant leakage, then reliability is improved, but manufacturing cost increases and assembly becomes more complex
Solution Approach 1:
The sealing function is merged into the structural design of the heat dissipation part itself. The insert-molded connection creates an integrated structure where the pipe and heat dissipation part form a unified leakage-proof assembly, eliminating the need for separate rubber rings or gaskets.
Solution Approach 2:
The insert-molding process itself provides the sealing function through the molecular bonding created during injection molding. The material flows around the inserted pipe part and bonds at the interface, creating a self-sealing structure that prevents leakage without requiring additional sealing components.
3Temperature
If complex cooling structures are used to improve cooling efficiency, then temperature control is improved, but device complexity increases and manufacturing efficiency decreases
Solution Approach 1:
The cooling channels and heat dissipation structure are combined into a single insert-molded component. The pipe part with integrated cooling channels is inserted into the heat dissipation part during molding, creating a complex cooling function within a single manufacturing step that would otherwise require multiple separate components and assembly operations.
Solution Approach 2:
The pipe part is pre-formed with its cooling channels and connection structures before being inserted into the heat dissipation part during the molding process. This preliminary formation of complex features in the insert component allows for efficient integration without requiring complex tooling or multiple manufacturing steps for the final assembly.
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 cooling efficiency, reduces manufacturing costs, and ensures electrical insulation while minimizing medium loss, making it applicable to various device sizes with improved design freedom.
Implementation Method 1
a heat dissipation part that is coupled to an external busbar and receives heat from the busbar
Implementation Method 2
a pipe part that is coupled to the heat dissipation part and in which a heat transfer medium receiving the heat flows
Data Source
AI summary
A cooling module is disclosed. A cooling module according to an aspect of the present disclosure comprises a heat dissipation part which is coupled to an external busbar and receives heat from the busbar, and a pipe part which is coupled to the heat dissipation part and inside which a heat transfer medium that receives the heat flows, wherein the heat dissipation part may comprise: a heat dissipation body formed to extend in one direction; a pipe coupling part which extends along the one direction inside the heat dissipation body and of which each end in the one direction is formed to be open so that the pipe part is coupled by penetrating therethrough; and a busbar coupling part which is positioned adjacent to the pipe coupling part and to which the busbar is coupled.