Rigid Coolant Manifold Connection for Battery Tolerance Compensation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery coolant distribution systems require significant manual labor for assembly due to individual screwing of connection elements and sealing, and are prone to detachment from battery cooling profiles due to tolerances and vibrations.

Innovation Solution

A coolant collection device featuring rigid coolant collection tubes and a T-shaped connecting piece with a floating arrangement, allowing axial adjustment to compensate for tolerances and simplify assembly, while ensuring a secure connection through a fixing unit and sealing elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flexible hoses with fittings are used to connect coolant collection channels to cooling profiles, then the connection can accommodate tolerances, but the assembly requires significant manual labor and multiple sealing elements

Engineering Contradiction:

Improvetolerance accommodationVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The connection system is divided into modular components: cooling profiles with integrated connection elements, coolant collection channels with corresponding connection elements, and a manifold. Each segment has standardized connection features that simplify assembly while accommodating tolerances through the rigid connection geometry.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection elements are merged directly into the cooling profiles and coolant collection channels as integral features, eliminating the need for separate flexible hoses and fittings. This integration reduces the number of components and sealing elements while maintaining tolerance accommodation through precise geometric matching.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If individual connection elements are screwed onto cooling profiles and coolant collection channels, then secure connections are achieved, but assembly time and manual labor increase significantly

Engineering Contradiction:

Improveconnection securityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Connection elements are pre-integrated into the cooling profiles and coolant collection channels during manufacturing. The connection features are prepared in advance with precise geometry, allowing for rapid assembly without requiring on-site screwing or complex fitting operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The traditional screw-threaded mechanical connection system is replaced with a simplified rigid connection system using integrated connection elements that engage through direct insertion or snap-fit mechanisms, eliminating the need for threading operations and reducing assembly steps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If cooling profiles have tolerances of approximately 1.5 mm, then manufacturing flexibility is improved, but precise alignment of connection elements becomes difficult

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The connection system is designed with tolerance compensation parameters built into the geometry of connection elements. The connection features incorporate dimensional tolerances and alignment features that absorb the 1.5 mm manufacturing variations, allowing components to self-align during assembly without requiring high-precision machining.

Inventive Principle:

Principle #35Parameter changes

4Stability of the object's composition

If rigid coolant collection tubes are used, then connection stability is improved, but adaptability to tolerance variations decreases

Engineering Contradiction:

Improveconnection stabilityVSAvoidtolerance compensation

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The rigid coolant collection tubes incorporate localized flexible connection features at their ends, such as integrated sealing elements or alignment features, while maintaining rigid bodies along their length. This allows the majority of the tube to remain stable and rigid for structural integrity, while the local connection zones provide adaptability to tolerance variations.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4573617B1Coolant collection device with rigid tube connections

Publication Date: 2026.03.25 SIEMENS MOBILITY GMBH

Figure 1
Figure 2
Figure 3

AI summary

The invention relates to a coolant collection device (1). The coolant collection device (1) has at least two rigid coolant collection tubes (2) and a T-shaped connecting piece (3) with three tubular connecting elements (3a, 3b, 3c). The T-shaped connecting piece (3) is arranged between the rigid coolant collection tubes (2) and a first (3a) of the three tubular connecting elements (3a, 3b, 3c) is designed to be received in a coolant channel (4) of a battery cooling profile (5), wherein the second (3b) and third (3c) of the three tubular connecting elements (3a, 3b, 3c) are each connected to the coolant collection tubes (2). A battery coolant distribution system (10) for a vehicle (16) is also described. A vehicle (16) is also described. A method for producing a coolant collection device (1) is also described. In addition, a method for producing a battery coolant distribution system (10) is described.