Manifold Case Assembly With Joint Rings for Tube Sealing
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Solution Overview
Problem
Existing thermal management systems for electric vehicle batteries face challenges such as complex assembly, laborious installation, and unreliable sealing due to rigid connections between tubes and connectors, which hinder efficient mass production and reliability.
Innovation Solution
A manifold case with a linking member and joint rings that allows for simplified assembly and mechanical retention, featuring adapters and connectors that can move between assembly and working positions, ensuring reliable sealing and indexing of tubes, and utilizing snap-on connections for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tubes are rigidly connected to connectors by brazing, then connection strength is improved, but assembly complexity and labor increase
Solution Approach 1:
The system divides the connection into separate components: a rigid manifold with connectors and flexible tubes with joints. This segmentation allows the rigid parts to maintain structural strength while the flexible tube absorbs assembly variations, eliminating the need for complex brazing operations and reducing assembly complexity.
Solution Approach 2:
The patent changes the connection parameter from rigid (brazing) to flexible (mechanical coupling with tolerance). The tube joint includes a coupling element that mechanically connects to the connector, providing sufficient connection strength without requiring high-temperature brazing processes, thereby simplifying assembly.
2Reliability
If brazing is used to connect tubes and connectors, then connection reliability is improved, but assembly time and labor cost increase
Solution Approach 1:
The tube joints are pre-assembled with coupling elements before installation into the manifold. This preliminary action ensures proper alignment and connection readiness, allowing for quick insertion into the manifold without requiring time-consuming brazing operations during final assembly, thus maintaining reliability while reducing assembly time.
3Reliability
If complex assembly procedures are used to ensure sealing, then sealing reliability is improved, but manufacturing efficiency decreases
Solution Approach 1:
The joint ring in the tube joint automatically performs the sealing function when the coupling element is inserted into the connector. The sealing action is self-actuating through the mechanical coupling, eliminating the need for complex external sealing procedures or multiple assembly steps, thereby maintaining sealing reliability while significantly improving manufacturing efficiency.
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 simplified and efficient assembly process with reliable sealing and mechanical retention, reducing assembly force and complexity, while ensuring effective thermal management for battery packs.
Implementation Method 1
a second position, called working position, in which the joint rings are capable of being compressed and/or deformed between the manifold 500A and the linking member
Data Source
AI summary
A manifold case for a fluid for connecting to tubes, includes a manifold and a linking member having adapters, the manifold including a column provided according to a longitudinal axis with a plurality of connectors spaced apart from each other, each connector defines a passage for flow of the fluid provided with a free end which defines an orifice for flow of the fluid, the connectors and the adapters are capable of being received by each other, and the manifold case including a plurality of joint rings, each ring is disposed between one of the connectors and one of the adapters. The linking member includes: a first position, in which the adapters are capable of receiving tubes so that each tube passes through one of the rings the linking member, a second position, in which the joint rings are capable of being compressed.