Split Heat Exchange Pipe Joint for Battery Pack Repair Access
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Solution Overview
Problem
The complexity of maintaining heat exchange pipe joints in battery packs is heightened by their one-piece design, which requires disassembly of internal components to access and repair, complicating the detachment and installation process due to limited space.
Innovation Solution
A split-structure heat exchange pipe joint design, where the first and second pipes are separately formed and detachably connected to an installation plate, allowing for easy detachment and installation without removing other components, facilitated by a through-hole, flanges, sealing members, and a fastener for secure and leak-proof connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece heat exchange pipe joint is used, then the structural integrity and sealing performance are improved, but the ease of repair and maintenance deteriorates due to the inability to detach the joint without disassembling other components
Solution Approach 1:
The heat exchange pipe joint is divided into multiple separable parts: a first pipe connected to the first side of the installation plate, a second pipe connected to the second side, and a connection component joining the two pipes. This segmentation allows each part to be independently detached and reinstalled, enabling maintenance without disassembling other battery pack components while maintaining reliable sealing through dedicated sealing members at each connection interface.
2Ease of manufacture
If a one-piece heat exchange pipe joint is used, then the manufacturing simplicity is improved, but the device complexity for maintenance operations increases due to the need to detach other components
Solution Approach 1:
The joint is segmented into modular components that can be manufactured separately using standard piping and connection technologies, then assembled together. This approach maintains manufacturing simplicity while reducing operational complexity during maintenance, as each module can be independently handled and replaced without manipulating the entire assembly or surrounding battery components.
Solution Approach 2:
The connection between pipe parts is designed to be dynamically changeable between connected and detached states through detachable connection mechanisms. This dynamic capability allows the system to transition from a fixed one-piece configuration to a separable configuration during maintenance, reducing the complexity of maintenance operations without compromising the structural integrity during normal operation.
3Volume of moving object
If the heat exchange pipe joint is designed as one piece, then the space efficiency is improved, but the ease of operation for detachment and installation deteriorates due to limited internal space
Solution Approach 1:
By segmenting the joint into smaller modular components, each part requires less space for manipulation during installation and maintenance. The modular design allows technicians to work with individual smaller pieces rather than a large one-piece assembly, significantly improving ease of operation within the limited internal space of the battery pack while maintaining compact overall dimensions.
Data Source
AI summary
A heat exchange pipe joint includes a first pipe and a second pipe that are separately formed and in communication with each other. The first pipe is detachably connected to a second side of the installation plate, and the second pipe is detachably connected to a first side of the installation plate. When the heat exchange pipe joint is applied to the battery pack, the heat exchange pipe joint in a split-structure requires a small operation space for detachment and installation. In this case, a process of taking out the entire heat exchange pipe joint from the case can be avoided. In this way, the detachment and installation of the heat exchange pipe joint can be easy and convenient, thereby facilitating the reparation process thereof.