Headerbox Tube Connection with Compressed Seal Ring Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal management systems for electric and hybrid vehicle batteries face challenges in assembly efficiency, reliability of seals, and complexity in connecting tubes and connectors, leading to laborious and costly manufacturing processes.
Innovation Solution
A fluid collecting box with a collector ramp and connecting member featuring adapters and joint rings that allow for simplified assembly through a relative movement, providing reliable sealing and mechanical maintenance without the need for special tools, and enabling easy indexing and guiding of tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tubes are secured to connectors by brazing, then reliable sealing is achieved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the brazing process (thermal/chemical joining) with a mechanical pressing system. The pressing device applies radial compression force to deform the tube elastically onto the connector, creating a mechanical interference fit that provides reliable sealing without requiring brazing equipment or thermal processes.
Solution Approach 2:
The tube's own elastic properties are utilized to achieve the sealing function. The radial compression deforms the tube elastically, and the tube's elastic recovery maintains continuous contact pressure against the connector, providing self-sustaining sealing without additional fastening elements or complex assembly mechanisms.
2Reliability
If traditional tube-connector assembly methods are used, then reliable connection is achieved, but assembly time and labor cost increase
Solution Approach 1:
The pressing device features multiple pressing elements arranged circumferentially that can simultaneously press multiple tubes in parallel. This segmentation of the pressing function across multiple independent elements enables high-speed assembly of multiple tube-connector connections in a single operation, dramatically improving productivity while maintaining connection reliability.
Solution Approach 2:
The pressing elements are pre-positioned and configured to apply radial compression force automatically when the tube is inserted. The device performs the sealing action as part of the insertion process itself, eliminating separate sealing steps and reducing assembly time while ensuring reliable connections.
3Reliability
If complex sealing structures are implemented in connectors, then sealing performance improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent utilizes the tube itself as a flexible sealing element. The tube's elastic deformation under radial compression creates an effective seal against the connector's sealing surface. This approach eliminates the need for complex rigid sealing structures within the connector, simplifying connector manufacturing while achieving reliable sealing through the flexible tube material.
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 efficient, reliable, and cost-effective assembly of thermal management systems by simplifying the connection process between tubes and connectors, ensuring tight seals and mechanical integrity, thus improving the thermal management of battery packs.
Implementation Method 1
the seal rings are capable of being compressed and/or deformed between the collector ramp (500A) and the connecting member
Implementation Method 2
the seal rings are capable of being compressed and/or deformed
Data Source
Figure 1~2
Figure 3~4
Figure 5~5A
AI summary
The invention relates to a fluid collection box (100) for connecting to tubes (20), comprising a collection manifold (500A) and a connecting member (300A) having adapters (200A), the collection manifold comprising a column (520A) provided along a longitudinal axis with a plurality of connectors (600A) spaced apart from each other, each connector delimiting a fluid flow passage having a free end which delimits a fluid flow orifice (650A), the connectors and the adapters are suitable for receiving each other, and the collection box (100) comprising sealing rings (400A), each ring is disposed between one of the connectors and one of the adapters.The connecting element comprises: a first position, in which the adapters are suitable for receiving tubes so that each tube passes through one of the rings of the connecting element, a second position, in which the sealing rings are likely to be compressed.