Liquid-Cooling Cooler Frame Structure for Friction Stir Welding
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Solution Overview
Problem
Automotive liquid-cooling coolers face challenges in joining reliability with intermediate components due to poor performance in high temperature and humidity environments, requiring extensive manufacturing time for reliable attachment.
Innovation Solution
An automotive liquid-cooling cooler structure utilizing a reserved structure configured for joining the liquid-cooling cooler body to an outer frame via friction stir welding, with specific planar and arc-shaped structures forming solid-state welded portions to enhance reliability and reduce manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods are used to connect the liquid-cooling cooler body to the outer frame, then the joining process is simple, but the joining reliability is poor in high temperature and humidity environments
Solution Approach 1:
The patent changes the joining method from traditional mechanical connection to friction stir welding, which fundamentally alters the joining parameters and process characteristics. This solid-state welding process creates a metallurgical bond that maintains high reliability in high temperature and humidity environments without requiring extensive manufacturing time for assembly and testing
Solution Approach 2:
The patent replaces traditional mechanical joining systems with friction stir welding, which uses mechanical friction and stirring action to create a solid-state weld. This substitution eliminates the need for complex mechanical fasteners and adhesive bonding, achieving both high reliability and efficient manufacturing
2Reliability
If traditional joining methods are used to connect the liquid-cooling cooler body to the outer frame, then the manufacturing process is fast, but the joining reliability is poor in high temperature and humidity environments
Solution Approach 1:
The patent transforms the joining process parameters from simple mechanical assembly to friction stir welding parameters, including rotational speed, traverse speed, and welding force. These parameter changes enable reliable joining in harsh environments while maintaining manufacturing efficiency through a standardized welding process
Solution Approach 2:
The patent introduces a reserved structure with specific geometric features that are segmented into the outer frame design. This segmentation allows the friction stir welding process to access and join specific regions, achieving high reliability without complicating the overall manufacturing process
3Reliability
If friction stir welding is used to join the liquid-cooling cooler body to the outer frame, then the joining reliability is improved, but the device complexity increases
Solution Approach 1:
The patent incorporates a reserved structure in advance during the design phase, which includes specific geometric features and material provisions. This preliminary action prepares the structure for friction stir welding, ensuring high joining reliability without requiring additional complex components or post-processing operations
Solution Approach 2:
The reserved structure serves multiple functions: it provides the geometric features needed for friction stir welding access, ensures proper alignment between the cooler body and outer frame, and creates the metallurgical bond. This multi-functionality reduces overall device complexity while achieving high joining 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 solution enhances joining reliability and reduces manufacturing time by using friction stir welding to create solid-state welded portions between the cooler body and frame, improving the structural integrity and efficiency of the cooling system.
Implementation Method 1
the reserved structure is configured for joining the liquid-cooling cooler body to the outer frame by friction stir welding
Implementation Method 2
the first heat-dissipating surface is in contact with the cooling liquid, the second heat-dissipating surface is in contact with a first power component set, a second power component set, and a third power component set
Data Source
AI summary
An automotive liquid-cooling cooler structure includes a liquid-cooling cooler body, an outer frame, and a reserved structure. The liquid-cooling cooler body is located in a frame opening of the outer frame, the reserved structure is located at a gap between the liquid-cooling cooler body and the outer frame, and the reserved structure is configured for joining the liquid-cooling cooler body to the outer frame by friction stir welding.