Plate Cooling Manifold Assembly for Leak-Safe Flexible Insertion
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Solution Overview
Problem
Existing thermal regulation devices for electrical and electronic components, such as power electronic devices and electrical energy storage elements, lack flexibility in component insertion and efficient heat transfer fluid flow, particularly during assembly and operation.
Innovation Solution
A thermal regulation device with complementary hollow connectors having male and female parts, fitted together to form a mechanical joint, allowing flexible component insertion and ensuring efficient heat transfer fluid circulation between pairs of plates, with sealing gaskets for leak-proof connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plates are brazed together to ensure sealing, then sealing reliability is improved, but assembly flexibility and ease of insertion are worsened
Solution Approach 1:
The manifold is divided into multiple separate connector elements that are mechanically assembled together rather than brazed as a single unit. This segmentation allows the manifold to be assembled in stages, providing flexibility during component insertion while maintaining sealing integrity through gaskets at the mechanical joints.
Solution Approach 2:
Gaskets are introduced as intermediary sealing elements at the mechanical joints between connector elements. These gaskets provide the sealing function that would otherwise require brazing, but allow for mechanical assembly and disassembly, thus providing assembly flexibility while maintaining sealing reliability.
2Strength
If connectors are rigidly fixed to plates, then structural strength is improved, but flexibility during component insertion is worsened
Solution Approach 1:
The connector elements are designed with mechanical joints that allow for controlled movement and adjustment during assembly. The connectors can be assembled in a sequence that accommodates component insertion, and the mechanical joints provide enough compliance to allow for alignment adjustments while maintaining structural integrity once assembled.
Solution Approach 2:
The manifold connectors are pre-assembled into sub-assemblies before final assembly with the thermal regulation device. This preliminary assembly allows for optimization of the connector structure to provide both strength and flexibility, and enables the manifold to be assembled in stages that accommodate component insertion requirements.
3Reliability
If brazing is used to join manifolds to plates, then sealing is improved, but manufacturing complexity and cost are worsened
Solution Approach 1:
The brazing process is replaced with mechanical joining using threaded or bayonet-style connectors. This substitution eliminates the need for high-temperature brazing equipment and processes, reducing manufacturing complexity and cost while maintaining sealing integrity through gasket-based sealing at the mechanical joints.
Solution Approach 2:
The gaskets used in the mechanical connectors are designed as simple, inexpensive sealing elements that can be easily replaced if needed. This approach is more economical than brazing, as the gaskets are cheap components that provide sufficient sealing for the application without requiring complex manufacturing processes.
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 provides flexible assembly, prevents damage to fluidic contact areas, and ensures uniform cooling of components by optimizing heat transfer fluid flow, enhancing the thermal regulation process.
Implementation Method 1
pairs of plates (3, 3'), arranged in at least one row, defining between them a heat transfer fluid circulation channel
Implementation Method 2
thermal regulation device for at least one electronic and/or electrical component... efficient cooling of electrical and/or electronic components
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a thermal regulation device (1) for at least one electronic and/or electrical component, in particular for a motor vehicle, having a stack of at least two pairs (5) of plates (3), defining circulation channels for heat-transfer fluid, and at least one heat-transfer fluid manifold (7), in fluidic communication with the circulation channels for heat-transfer fluid. According to the invention, said at least one heat-transfer fluid manifold (7) has at least two complementary hollow manifolds (9). Each manifold (9) is joined to an associated pair (5) of plates (3) and comprises a distribution zone having at least one slot leading into the circulation channel for heat-transfer fluid. The manifolds (9) joined to two adjacent pairs (5) of plates (3) comprise a male part (93) and a complementary female part (95) that are fitted one in the other, the male part (93) bearing at least one seal (11). The invention also relates to a corresponding method for assembling such a device.