Spin-Welded Plastic Coolant Fitting for Leak-Safe Hybrid Modules
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Solution Overview
Problem
Existing plastic coolant fittings for hybrid modules lack efficient and cost-effective manufacturing methods that balance durability and cost, particularly in the connection and sealing of coolant tubes, which affects the overall performance and reliability of the hybrid drive system.
Innovation Solution
A plastic coolant fitting design featuring separate upper and lower coolant tubes made from different materials, connected via spin welding with complementary trapezoidal cross-sections and sealed with EPDM seals, and featuring metal compression limiter tubes to prevent deformation and enhance mounting, allowing for economical injection molding and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate upper and lower coolant tubes are made from different materials and connected via spin welding, then manufacturing cost and durability are improved, but manufacturing complexity increases
Solution Approach 1:
The coolant fitting is divided into separate upper and lower coolant tubes made from different materials (glass fiber reinforced polyamide 66 and polyamide 66 respectively). Each tube is manufactured independently through injection molding, allowing optimization of material selection and manufacturing processes for each segment, thereby reducing overall manufacturing cost while maintaining durability.
Solution Approach 2:
A spin welding connection mechanism is introduced as an intermediary joining method between the upper and lower coolant tubes. The complementary trapezoidal cross-sections with ring-shaped groove and protrusion enable precise alignment and effective spin welding, facilitating the assembly of different materials while controlling manufacturing complexity through standardized connection geometry.
2Strength
If complementary trapezoidal cross-sections with ring-shaped groove and protrusion are used for spin welding, then connection strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
Complementary asymmetric trapezoidal cross-sections are designed for the upper and lower coolant tubes, with the upper tube featuring a ring-shaped groove and the lower tube featuring a ring-shaped protrusion. This asymmetric geometry provides inherent alignment features that guide the spin welding process, enhancing connection strength while the standardized trapezoidal shape keeps manufacturing precision requirements within achievable limits for injection molding.
3Reliability
If EPDM seals and metal compression limiter tubes are added for sealing and mounting, then sealing reliability is improved, but device complexity increases
Solution Approach 1:
EPDM seals are introduced as intermediary sealing elements between the coolant tubes and mounting surfaces. The metal compression limiter tubes serve as intermediary components that distribute mounting forces and prevent deformation of the plastic mounting flanges. These intermediary elements significantly improve sealing reliability and mounting durability while adding only moderate complexity through standardized seal and limiter tube designs.
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 a durable, cost-effective, and reliable coolant fitting with enhanced sealing and mounting capabilities, reducing manufacturing complexity and ensuring efficient coolant flow while preventing fluid leakage, thus improving the performance and reliability of hybrid module cooling systems.
Implementation Method 1
the second straight section is fixed to the rounded section by spin welding
Data Source
AI summary
A plastic coolant fitting for a hybrid module includes an upper coolant tube with a first straight section and a rounded section, and a lower coolant tube with a second straight section fixed to the rounded section by spin welding. The rounded section may include a ring-shaped groove and the second straight section may include a ring-shaped protrusion installed in the ring-shaped groove. Prior to spin welding, the ring-shaped groove and the ring-shaped protrusion may include respective complementary trapezoidal cross-sections.