Thermal Management Connector for Thin-Walled Heat Exchangers
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Solution Overview
Problem
Existing thermal management systems for vehicles, such as those in electrical vehicles, face challenges in reducing weight while maintaining structural integrity and efficiency, particularly with thicker heat exchanger walls and the need for threaded connectors which complicate the design and assembly of thin-walled heat exchangers.
Innovation Solution
A lightweight connector design that eliminates the need for threaded bores in heat exchanger panels, allowing for thinner walls (<6mm) and eliminating the requirement for separate support rings, enabling easy installation by drilling through parallel walls and using a cap device with internal/external threads for a secure, leak-tight connection, which can be assembled on-site or in a separate assembly line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded connectors are used in heat exchanger panels, then connection strength is improved, but heat exchanger wall thickness must be increased
Solution Approach 1:
The connector is divided into separate components: a fastening element that passes through the panel and a separate threaded insert or locking mechanism. This allows the threaded connection to be made in the connector itself rather than requiring thick panels, enabling thin-walled heat exchangers to achieve strong connections without increasing wall thickness.
Solution Approach 2:
A threaded insert or intermediate fastening component is introduced as a mediator between the thin panel wall and the connector. This intermediary element provides the threading function without requiring the panel itself to be thick, thus resolving the contradiction between connection strength and wall thickness.
2Reliability
If separate support rings are added for connector installation, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The support function previously requiring separate rings is merged into the connector body itself. The connector is designed with integrated reinforcement features or a structure that inherently provides the necessary support without requiring additional separate components, thus maintaining reliability while reducing complexity.
Solution Approach 2:
The connector is designed to be self-supporting, with its own structure providing the necessary reinforcement and support functions. The connector body includes integrated features that eliminate the need for separate support rings, making the system simpler while maintaining connection reliability.
3Reliability
If complex assembly procedures are used, then connection durability is improved, but manufacturing time increases
Solution Approach 1:
The connector is pre-assembled with its fastening elements and sealing components in a controlled manufacturing environment. This preliminary assembly ensures proper alignment and sealing, allowing for quick and simple installation in the field without requiring complex assembly procedures, thus maintaining durability while improving assembly speed.
Solution Approach 2:
Complex mechanical assembly procedures are replaced with simpler fastening mechanisms such as snap-fit connections, bayonet mounts, or simple screw-fastening systems. These mechanisms provide durable connections through their design rather than through complex assembly steps, enabling quick installation while maintaining connection durability.
Data Source
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AI summary
The present invention relates to an arrangement for thermal management of thermally conditioned objects, such as electric batteries. The arrangement comprises connectors (1, 1') for the inlet and outlet of a medium to and from heat exchangers (10). The heat exchangers may be of a thin flat design and made out of extruded aluminium metal or an extruded aluminium alloy, and further having several parallel channels (14). The invention also relates to a method for assembly of the arrangement. The invention can be applied in solutions for thermal management of batteries in electric vehicles.