Battery Cooling Plate Connection Geometry for Reliable Solder Joining
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Solution Overview
Problem
Existing heat exchanger plates face challenges in achieving a functionally and technically improved assembly of connecting pieces to the plate body, leading to process unreliability and increased costs due to complex joining methods.
Innovation Solution
A heat exchanger plate design featuring a plate body composed of two plate elements with connecting pieces having a connection section oriented parallel to the plane, joined via a receiving section with complementary longitudinal webs and grooves, optimized for a uniform joining gap and material bond using soldering, ensuring a robust and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connecting pieces are joined to the plate body using conventional shaping or machining methods, then the connecting pieces can be manufactured, but the joining process becomes complex and unreliable
Solution Approach 1:
The connection section of the connecting piece is designed with pre-formed longitudinal grooves that guide the joining process. The plate body elements are prepared with corresponding receiving sections that fit into these grooves, establishing the correct geometry and alignment before the actual joining operation occurs. This preliminary geometric preparation ensures reliable joining while simplifying the manufacturing process.
Solution Approach 2:
Solder material is introduced as an intermediary substance between the connection section of the connecting piece and the receiving section of the plate body. The solder flows into the longitudinal grooves and fills the interface, creating a strong metallurgical bond that simplifies the joining process and eliminates the need for complex mechanical fastening or welding operations.
2Ease of manufacture
If the connecting piece is joined with a complex joining method, then the connection strength may be sufficient, but the assembly becomes less friendlY and costs increase
Solution Approach 1:
The invention replaces complex mechanical joining systems (such as threading, riveting, or welding) with a simplified soldering process. The longitudinal grooves in the connection section are designed to guide and contain the solder material, allowing the solder to automatically form strong bonds as it cools, eliminating the need for complex mechanical assembly operations while maintaining high connection strength.
Solution Approach 2:
The joining process utilizes parameter changes in the solder material, specifically its melting and solidification characteristics. The solder is applied in a molten state that allows it to flow into the longitudinal grooves and wet the mating surfaces, then it solidifies to create a strong, rigid connection. This phase change enables simple assembly operations to produce strong joints.
3Manufacturing precision
If the joining gap is not uniform, then the joining process becomes difficult, but maintaining uniform gap requires high manufacturing precision
Solution Approach 1:
The connection section of the connecting piece is pre-formed with longitudinal grooves that have precise geometry and uniform spacing. These grooves are created during the manufacturing of the connecting piece itself, establishing the correct gap dimensions before assembly. This preliminary precision work eliminates the need for complex gap control mechanisms during the joining process.
Solution Approach 2:
The longitudinal grooves in the connection section serve a dual function: they guide the solder material during joining and simultaneously maintain the uniform gap between the connecting piece and plate body. The grooves self-regulate the gap width through their geometric constraints, eliminating the need for external fixtures or complex positioning systems to maintain gap uniformity.
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 enables a high-strength, assembly-friendly, and cost-effective joining of connecting pieces, reducing flow resistance and scrap rates while maintaining tightness and process reliability.
Implementation Method 1
The plate elements are joined by soldering, incorporating the connection section of the connecting piece in the receiving section of the plate body
Data Source
AI summary
A cooling plate for battery cooling has a plate body formed from two plate elements and a connecting piece for a cooling fluid. The connecting piece has a connection section which is joined in a receiving section of the plate body formed between the plate elements. The connection section has two arcuate wall sections in cross section and two opposing, outwardly directed longitudinal webs. The receiving section has longitudinal grooves extending between the plate elements in the area of the joining plane. The longitudinal webs run in the longitudinal grooves.