Plastic-Manifold Cooling Component With Fluid-Tight Thermal Joining
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Solution Overview
Problem
Existing cooling components for objects like battery systems and power electronics require time-consuming welding or soldering of metal connection parts, which are not necessary for heat transfer and can be counterproductive, and there is a need for a more cost-effective and thermally efficient solution.
Innovation Solution
A cooling component with a plastic connection part featuring three-dimensional nanostructures and microstructures, connected to a metallic cooling body using direct thermal joining, allowing for a stable and cost-effective fluid-tight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal connection parts are welded or soldered to the cooling body, then a fluid-tight connection is achieved, but the manufacturing process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the mechanical joining processes of welding or soldering with an injection molding process. The connection part is injected directly onto the cooling body in one step, eliminating the need for separate welding or soldering operations. This substitution of manufacturing methods significantly reduces manufacturing time while maintaining the fluid-tight connection requirement.
Solution Approach 2:
The patent incorporates the connection part directly onto the cooling body during the injection molding process before any subsequent assembly steps. By performing the joining action during the primary manufacturing process rather than as a separate subsequent operation, the overall manufacturing time is reduced while ensuring the fluid-tight connection is established early in the production sequence.
2Strength
If metal connection parts are used, then a strong mechanical connection is achieved, but heat transfer efficiency decreases due to unwanted heat transfer to the connection part
Solution Approach 1:
The patent employs a composite structure where the cooling body is made of metal for optimal heat conduction, while the connection part is made of plastic with lower thermal conductivity. This material combination allows the metal cooling body to efficiently transfer heat from the object being cooled, while the plastic connection part acts as a thermal barrier, preventing unwanted heat transfer to the cooling medium supply and discharge lines, thus improving overall heat transfer efficiency.
Solution Approach 2:
The patent applies different material properties to different parts of the cooling component. The cooling body uses metal with high thermal conductivity for effective heat dissipation, while the connection part uses plastic with lower thermal conductivity to minimize parasitic heat transfer. This local differentiation of material properties optimizes both heat transfer efficiency and mechanical connection strength in their respective locations.
3Loss of energy
If plastic connection parts are used, then heat transfer efficiency is improved by preventing unwanted heat transfer, but the manufacturing precision and fluid-tight connection become more difficult to achieve
Solution Approach 1:
The patent incorporates the connection part directly onto the cooling body during the injection molding process before any subsequent assembly steps. By performing the joining action during the primary manufacturing process rather than as a separate subsequent operation, the overall manufacturing time is reduced while ensuring the fluid-tight connection is established early in the production sequence.
Solution Approach 2:
The patent replaces the mechanical joining processes of welding or soldering with an injection molding process. The connection part is injected directly onto the cooling body in one step, eliminating the need for separate welding or soldering operations. This substitution of manufacturing methods significantly reduces manufacturing time while maintaining the fluid-tight connection requirement.
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 use of plastic connection parts with nanostructures provides a cost-effective and thermally advantageous solution, preventing unwanted heat transfer and enabling efficient heat dissipation while maintaining a stable connection.
Implementation Method 1
heating the connecting faces of the cooling body, in particular via induction, to a temperature which corresponds at least to the melting temperature of the plastic of the connection part
Implementation Method 2
connecting all heated connecting faces of the cooling body to the respectively opposing connecting face of the connection part in a fluid-tight manner by pressing these mutually opposing connecting faces together with fusion of the connecting face of the connection part through the heat of the connecting face of the cooling body
Data Source
AI summary
A cooling component and method for producing a cooling component, having an elongated cooling body made of metal or metal alloy, with which an object may be cooled, wherein the cooling body has one or more medium channels for the throughflow of cooling medium, and having a connection part, which is connected to the cooling body in a fluid-tight manner and via which the cooling medium can be supplied to the cooling body and/or via which the cooling medium can be discharged from the cooling body. The connection part is made from plastic to connect the connection part to the cooling body, a first, which has a plurality of cooling faces, each with three-dimensional nanostructures and/or microstructures incorporated by physical and/or chemical nanostructuring or microstructuring methods, is incorporated in the receiving space of a receptacle of the connection part and is connected to the receptacle there in a fluid-tight manner.