MPE Tube-to-Header Adapter Joint Without Brazing Heat
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Solution Overview
Problem
Existing methods for connecting Multi Port Extrusion (MPE) tubing to headers often require brazing or welding, which can compromise mechanical properties and are unsuitable for coated MPE profiles that cannot withstand elevated temperatures, limiting their application in cooling systems like battery thermal management.
Innovation Solution
A connection system using an adapter with mechanical fixation means, such as snap-on connections and a seal ring, between the MPE tubing and header, allowing for on-site assembly without heat treatment, suitable for both coated and uncoated profiles, using materials like plastic and aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing or welding is used to connect MPE tubing to header, then connection strength is improved, but mechanical properties of the connected parts are compromised and coated MPE profiles cannot be used
Solution Approach 1:
An adapter made of plastic material is introduced as an intermediary component between the MPE tubing and the header. The adapter connects to the MPE tubing via a first connection (e.g., insertion into a receiving part with adhesive or mechanical fixation) and to the header via a second connection (e.g., threading or additional fixation). This mediator allows the MPE tubing to remain unheated, preserving its mechanical properties and coating integrity, while still achieving a secure connection to the header through the adapter interface.
2Strength
If brazing or welding is used to connect MPE tubing to header, then connection strength is improved, but coated MPE profiles that cannot withstand elevated temperatures cannot be connected
Solution Approach 1:
The plastic adapter serves as a temperature-buffering intermediary that isolates the coated MPE tubing from the heat of brazing or welding operations. The adapter itself can be attached to the header using heat-based methods if needed, while the MPE tubing side requires no heat treatment, thus preserving the coating on temperature-sensitive MPE profiles.
Solution Approach 2:
The connection method transitions from high-temperature thermal processes (brazing/welding) to low-temperature or ambient-temperature mechanical connections (adhesive bonding, snap-fit, threading). This parameter change in connection temperature enables the use of coated MPE profiles that would otherwise be damaged by elevated temperatures.
3Ease of operation
If simple mechanical connections are used instead of brazing, then on-site assembly is facilitated and coated MPE profiles can be connected, but connection strength may be reduced
Solution Approach 1:
The connection system is segmented into multiple independent connection interfaces: the MPE tubing connects to the adapter via one mechanism (e.g., insertion and adhesive bonding), while the adapter connects to the header via another mechanism (e.g., threading or snap-fit). This segmentation allows each connection point to be optimized for its specific requirements and enables step-by-step assembly on-site without requiring complex heated equipment.
Solution Approach 2:
The invention replaces the thermal-mechanical system of brazing/welding with purely mechanical connection methods (threading, snap-fit, adhesive bonding). This substitution maintains connection strength through proper mechanical design while enabling simple on-site assembly without heat treatment equipment.
Data Source
AI summary
A connection between one end of a Multi Port Extrusion (MPE) tube (1) of aluminium or an aluminium alloy and one header (2), the connection comprises an adapter (3) with a seal ring (4) fixed between the MPE tube and the header. The invention also relates to a method for connecting said parts.