Building hybrid assemblies for optimising thermal management

Application: active cooling of energy storage devices and power electronics

Initial situation

An optimised heat loss discharge in energy reservoirs (e.g. batteries) and power electronics ensures high efficiency, longer service life and thus a more stable product performance. Cooling elements made of aluminium quickly remove excess heat. If they are encircled on the back by a cooling liquid flow, heat can be removed quite efficiently. This requires the media-impermeable connection of the cooling enclosure to the aluminium heat sink.

Solution

A compact design as well as cost-effective manufacturing of the cooling elements can be achieved by joining the aluminium component with a plastic injection moulding part, using thermal direct joining by hyJOIN® technology. Previously required screws and additional seals can be omitted because the connection is media-impermeable. In addition, flange widths and material thicknesses can be minimised, further reducing weight and creating space. In addition to the new degrees of freedom that come with the assemblies’ design, the hyJOIN® joining technology offered by KIST + ESCHERICH is ideally suited for automated production due to its intelligent process steering and control. This makes it possible to produce cooling elements at a lower cost and to maintain high process reliability.

Technical Consultancy