Hot-Forming Die for Brazed Heat Transfer Plate Duct Precision
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Solution Overview
Problem
Existing methods for producing heat transfer plates are inefficient and lack the technical advancements needed to produce high-quality cooling solutions for batteries in electric vehicles, which are sensitive to temperature distribution and prone to overheating.
Innovation Solution
A hot-forming die method involving a plate stack of metal elements with brazing material, where the stack is heated and clamped between a lower and upper die with spacer elements, internal pressure forms ducts, and the brazing material is melted to join the elements, allowing for efficient production of heat transfer plates with precise duct structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods for producing heat transfer plates are used, then production can be maintained with conventional equipment, but the production efficiency and quality are insufficient for high-performance battery cooling applications
Solution Approach 1:
The patent applies parameter changes by heating the plate stack to a specific temperature range (400-600°C) before deformation, which changes the material properties of the metal plates to make them more formable. This temperature parameter change enables the creation of complex duct structures with high precision while maintaining efficient production through a continuous heating and forming process
Solution Approach 2:
The patent uses hydraulic or pneumatic pressure systems to apply internal pressure to the plate stack during the forming process. This allows for controlled deformation of the plates into precise duct structures while maintaining production efficiency through automated pressure application and release cycles
2Manufacturing precision
If the plate stack is clamped tightly between dies to form precise duct structures, then manufacturing precision is improved, but the spacer elements cannot be removed easily after forming
Solution Approach 1:
The patent employs dynamic spacer elements that can change their state during the forming process. The spacers are designed to be movable rather than fixed, allowing them to be positioned during forming for precision and then removed or repositioned after forming. This dynamic approach enables both precise duct structure creation and easy spacer removal without compromising either requirement
Solution Approach 2:
The patent applies preliminary action by positioning the spacer elements before the forming process begins. The spacers are pre-positioned to define the duct geometry, then the forming process occurs, and finally the spacers are removed. This sequence of preliminary positioning followed by removal solves both the precision and ease of manufacture requirements
3Strength
If the plate stack is heated to high temperature for brazing, then the brazing material melts and joins the plate elements effectively, but the handling and positioning become more difficult
Solution Approach 1:
The patent replaces manual handling and positioning operations with automated mechanical systems during the heating process. Robotic or automated positioning systems are used to maintain precise plate stack alignment even at high temperatures, eliminating the difficulties of manual handling while ensuring strong brazed joints through consistent positioning
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
This method enables the production of high-quality heat transfer plates with optimized performance and operational efficiency, effectively regulating battery temperatures and preventing overheating in electric vehicles.
Implementation Method 1
heating the plate stack
Implementation Method 2
Melting the brazing material between the plate elements
Implementation Method 3
deforming, using internal pressure, at least one plate element region into the duct cavity
Implementation Method 4
Melting the brazing material between the plate elements and joining by brazing the plate elements at joining surfaces
Data Source
AI summary
A hot-forming die has a heatable lower die and a heatable upper die. The lower die and the upper die have spacer elements to permit flexing. A plate stack including two plate elements is inside the hot-forming die. The plate stack is on the spacer elements in the lower die. The lower die and the upper die are displaced relative to each other when the hot-forming die is closed. The spacer elements of the upper die come into contact with the plate stack. As the closing movement continues, the spacer elements, are displaced into the lower die and the upper die, respectively, and the plate stack is clamped between the lower die and the upper die. The plate stack is then heated by the lower die and the upper die and an internal pressure is applied to an intermediate space between the plate elements by feeding in an active medium.