Segmented Fluid Distribution Tank for U-Flow Battery Cooling
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Solution Overview
Problem
Conventional heat exchangers for battery cooling in electric and hybrid vehicles have complex end tank designs that increase assembly time and manufacturing costs, and lack a simple and cost-effective solution for U-flow cooling of battery cells.
Innovation Solution
A fluid distribution tank with a simple component design, featuring multiple compartments and easy-to-assemble joints, which includes a pair of plates with a connecting opening and dividing walls to create sub-chambers for efficient fluid flow, reducing pressure drop and facilitating easy assembly and retrofitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional end tank designs are used in heat exchangers, then the structural strength and sealing capability are maintained, but the assembly time and manufacturing cost increase due to complex component designs and complex joints
Solution Approach 1:
The end tank is divided into a first plate and a second plate that are coupled together to define a distribution chamber. This segmentation simplifies the manufacturing of each individual plate while maintaining the overall structural integrity and sealing capability of the end tank assembly.
Solution Approach 2:
Multiple functional features (distribution chamber, sub-chambers, inlet/outlet openings, connecting openings) are integrated into a single end tank structure formed by coupling two plates. This merging reduces the total number of separate components needed, thereby simplifying assembly and reducing manufacturing cost.
2Productivity
If conventional end tank designs are used in heat exchangers, then the sealing capability is maintained, but the assembly time increases due to complex joints
Solution Approach 1:
The end tank is segmented into two plates that can be separately manufactured and then coupled together. This segmentation allows for standardized joint designs that are easier to assemble while maintaining sealing reliability through consistent manufacturing of the coupling interfaces.
Solution Approach 2:
The design changes the structural parameters of the end tank by using two coupled plates instead of a single complex piece. This parameter change enables the use of simpler, more repeatable joining methods while maintaining the necessary sealing capability for fluid distribution.
3Device complexity
If a simple end tank design is used, then the manufacturing cost and assembly time are reduced, but the capability to enable U-flow passes through cooling tubes is compromised
Solution Approach 1:
The distribution chamber is divided into multiple sub-chambers using dividing walls, creating a simple yet effective configuration that enables U-flow passes. This segmentation provides the necessary fluid flow path control without requiring complex external components or structures.
Solution Approach 2:
The end tank design merges multiple functions (fluid distribution, flow direction control, cooling tube connection) into a single integrated structure. The dividing walls and chamber configuration work together to enable U-flow passes while maintaining design simplicity.
4Reliability
If conventional joints are used in end tanks, then the structural integrity is maintained, but the joining and sealing repeatability and service life are reduced
Solution Approach 1:
The end tank is divided into two plates that are coupled together, creating standardized joint interfaces. This segmentation allows for consistent manufacturing and assembly of the joints, improving repeatability and thereby extending the service life of the heat exchanger.
Solution Approach 2:
The design parameters of the joint configuration are optimized by using two coupled plates with defined connecting openings. This parameter change enables more reliable and repeatable joining while maintaining structural integrity, leading to improved service life.
Data Source
AI summary
A fluid distribution tank of a heat exchanger includes a pair of plates, including a first plate and a second plate, coupled with each other to define a distribution chamber with a connecting opening between the first plate and the second plate, the connecting opening being adapted to form connection between the fluid distribution tank and a tubular element of the heat exchanger, and at least one dividing wall located between the first plate and the second plate to divide the distribution chamber into at least two sub-chambers. Volumes of the individual sub-chambers are different from each other.