COOLING MODULE FOR BATTERIES OF AN ELECTRIC OR HYBRID VEHICLE

Abstract

A cooling module for batteries of an electric or hybrid vehicle has a coolant supply line, a coolant discharge line, and a plurality of flat tubes arranged side by side, between which there is space for batteries to be cooled, each of the flat tubes being connected to the coolant supply line or the coolant discharge line. The flat tubes each carry connectors. The coolant supply line and the coolant discharge line are each assembled from a plurality of line segments connected by a connector of one of the flat tubes to one of the connectors of an adjacent flat tube. A spacer strip is arranged between adjacent flat tubes. The spacer strip delimits between itself and each of the two adjacent flat tubes spaces for batteries that are to be cooled.

Claims

1. A cooling module for batteries of an electric or hybrid vehicle, the cooling module comprising: a coolant supply line; a coolant discharge line; a plurality of flat tubes arranged side by side, between which there is space for batteries to be cooled, each of the flat tubes being connected to the coolant supply line and the coolant discharge line; wherein the flat tubes each carry connectors and the coolant supply line and the coolant discharge line are each assembled from a plurality of line segments connected by a connector of one of the flat tubes to one of the connectors of an adjacent flat tube, and wherein a spacer strip is arranged between adjacent flat tubes, said spacer strip delimiting between itself and each of the two adjacent flat tubes spaces for batteries that are to be cooled.

2. The cooling module according to claim 1, wherein the flat tubes are corrugated.

3. The cooling module according to claim 1, wherein the connectors are attached to end pieces, which are attached to ends of the flat tubes.

4. The cooling module according to claim 3, wherein the flat tubes carry end pieces with connectors at opposite ends, and wherein the flat tubes run between the coolant supply line and the coolant discharge line.

5. The cooling module according to claim 3, wherein the flat tubes carry end pieces with connectors at only one end, and wherein the coolant supply line and the coolant discharge line run on the same side of the flat tubes, wherein the flat tubes each form at least two channels running side by side.

6. The cooling module according to claim 3, wherein the end pieces each carry connectors for the coolant supply line and the coolant discharge line.

7. The cooling module according to claim 1, wherein the spacer strips have an extension, with which they touch the coolant supply line and/or the coolant discharge line.

8. The cooling module according to claim 7, wherein the extension comprises an opening through which the coolant supply line or the coolant discharge line pass.

9. The cooling module according to claim 8, wherein the coolant supply line and the coolant discharge line are held in the openings by snap-in hooks.

10. The cooling module according to claim 9, wherein the opening has circumferential recesses accommodating the snap-in hooks of the coolant supply line or the coolant discharge line.

11. The cooling module according to claim 10, wherein the snap-in hooks extend from an abutment ring that abuts a rim of the opening.

12. The cooling module according to claim 1, wherein the spacer strips have the same thickness as the flat tubes

13. The cooling module according to claim 7, wherein the spacer strips comprise an intermittent groove that runs alternatingly on opposite sides of the spacer strip.

14. The cooling module according to claim 13, wherein the groove is arranged between bonding surfaces for bonding the spacer strip to a battery or battery cell by an adhesive, wherein in longitudinal direction of the spacer strip the bonding surfaces alternate with recessed surfaces.

15. The cooling module according to claim 14, wherein the recessed surfaces are bounded by webs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above-mentioned aspects of exemplary embodiments will become more apparent and will be better understood by reference to the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0024] FIG. 1 shows a schematic representation of an embodiment of a cooling module in accordance with this disclosure;

[0025] FIG. 2 shows a lateral view of the embodiment of FIG. 1;

[0026] FIG. 3 shows a sectional view to FIG. 1;

[0027] FIG. 4 shows a view of detail A of FIG. 3;

[0028] FIG. 5 shows a view of detail B of FIG. 3;

[0029] FIG. 6 shows a schematic representation of a further embodiment of a cooling module;

[0030] FIG. 7 shows a schematic detail of a further embodiment of a cooling module;

[0031] FIG. 8 shows a schematic cross-section of a detail of the embodiment of FIG. 7;

[0032] FIG. 9 shows a schematic cross-section of a detail of another embodiment;

[0033] FIG. 10 shows an end section of a spacer strip with line segments;

[0034] FIG. 11 shows a cross-section of a detail of FIG. 10;

[0035] FIG. 12 shows another view of the line segment of FIG. 10; and

[0036] FIG. 13 shows another view of the line segment of FIG. 10.

DESCRIPTION

[0037] The embodiments described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of this disclosure.

[0038] FIGS. 1 to 5 schematically show a cooling module for batteries of an electric or hybrid vehicle. The cooling module comprises a coolant supply line 1, a coolant discharge line 2, and a plurality of flat tubes 3. The flat tubes 3, located in parallel with one another, are connected to the coolant supply line 1 and the coolant discharge line 2. The flat tubes 3 run at right angles to the coolant supply line 1 and the coolant discharge line 2. Between adjacent flat tubes 3 there is space for batteries 7 to be cooled. The batteries 7 may, for example, be adhesively bonded to the sides of the flat tubes 3.

[0039] In the embodiment shown, the flat tubes 3 are of planar design, and are thus adapted to batteries 7 with a planar outer surface, for example, cuboid batteries. Alternatively, the flat tubes 3 may also be of corrugated design, for example, for circular cylindrical batteries. The flat tubes 3 may be made of metal, for example, an aluminium alloy, or plastic.

[0040] In the embodiment shown, the coolant supply line 1 and the coolant discharge line 2 are arranged at opposite ends of the flat tubes 3. The flat tubes 3 contain one or a plurality of channels extending from one end of the flat tube 3 to the opposite end. However, it is also possible that the coolant supply line 1 and the coolant discharge line 2 are arranged at the same end of the flat tubes 3. Then the flat tubes 3 contain at least two channels, namely an outward channel and a return channel. Each flat tube 3 may be provided with a plurality of outward channels and return channels in order to improve mechanical stability. Channels may be separated in the flat tube 3 by an inner wall or a weld seam that connects the front and rear sides of a flat tube 3. If the coolant supply line 1 and the coolant discharge line 2 are at the same end of the flat tubes 3, the flat tubes 3 carry at their end facing away from the coolant supply line 1 and the coolant discharge line 2, a deflector, not shown in the figures, which connects the outward channel with the return channel. The deflector may be connected to the flat tubes 3, for example, by means of a push-fit connection, a plug in-connection and/or a materially bonded connection, for example, in the form of brazing, welding or adhesive bonding.

[0041] The coolant supply line 1 and the coolant return line 2 are each assembled from a plurality of line segments, and are connected to the flat tubes 3 by way of connectors 6. Therein the connectors may for line segments or the connectors may connect line segments provided as separate parts. At their ends, at which the flat tubes 3 are connected to the coolant supply line 1 and the coolant return line 2, respectively, the flat tubes 3 carry an end piece 5, which is connected to the flat tubes 3 by means of a push-fit connection, a plug-in connection and/or by means of a partially bonded connection, for example, in the form of brazing, welding or adhesive bonding. The connectors 6 are attached to these end pieces 5, for example, by means of a partially bonded connection, and/or by means of a push-fit or plug-in connection.

[0042] In the embodiment shown in FIGS. 1 to 5, line segments of the coolant supply line 1 and the coolant discharge line 2 are inserted into connectors 6. In the connectors 6 line segments may be surrounded by sealing rings 12, in order to compensate for tolerances in the alignment of the connectors, and to prevent leakage.

[0043] In the embodiment shown in FIGS. 1 to 5, a spacer strip 8 is arranged between neighbouring flat tubes 3. Batteries 7 are held between one of the flat tubes 3 and one of the spacer strips 8. Thereby batteries 7 are cooled on one side only, namely on the side that abuts against one of the flat tubes 3, while the opposite side abutting a spacer strip 8 is not cooled. This is sufficient for many cases.

[0044] The spacer strips 8 may be made inexpensively of plastic, and can be provided, for example, with an extension 11 that touches the coolant supply line 1 and/or the coolant discharge line 2, e.g., with an U-shaped extension, a C-shaped extension, or an extension that has an opening through which the coolant supply line or the coolant discharge line passes. If the coolant supply line 1 and the coolant discharge line 2 are arranged on the same end of the flat tubes 3, the extension 11 may project between the coolant supply line 1 and the coolant discharge line 2 to facilitate positioning during assembly. An extension 11 of the spacer strips 8 that abuts the coolant supply line 1 and the coolant discharge line 2 facilitates assembly, especially if the extension has an opening for the coolant supply line 1 and/or the coolant discharge line 2. An opening, e.g., a U- or C-shaped opening or a through hole, facilitates correct positioning of coolant supply line 1 and the coolant discharge line 2 with respect to the spacer strips 8.

[0045] The cooling module can also be used to heat the batteries by passing heated coolant through the cooling module. In frosty conditions, batteries at the edge of the cooling module often have an increased heating requirement, and it can therefore be advantageous to dispense with spacer strips 8 only in an end section of the cooling module, and to arrange the flat tubes 3 at correspondingly smaller distances from one another, so that such batteries abut against flat tubes on both sides.

[0046] FIG. 4 shows detail A of FIG. 3 and FIG. 5 shows detail B of FIG. 3. FIGS. 3 to 5 show in detailed views, an end section of a flat tube 3 of the above-described cooling module, together with an end piece 5, attached to the flat tube 3 and carrying a connector 6 for purposes of connecting a line section of the coolant supply line 1 or the coolant discharge line 2.

[0047] The connector 6 surrounds an end section of a line segment of the coolant supply line 1 or the coolant discharge line 2. The line segment carries an annular seal 12, e.g., an O-ring in a groove.

[0048] It is also possible that the end piece 5 has an inner part in addition to connector 6. The connector 6 surrounds this inner part, which may carry an annular seal 10, for example, an O-ring, in an annular groove. The line section of the coolant supply line 1 or the coolant discharge line 2 then surrounds this inner part and projects into the connector 6, that is to say, it lies between the connector 6 and the inner part 9.

[0049] FIG. 6 shows schematically another embodiment of a cooling module for batteries of an electric or hybrid vehicle. This embodiment differs from the embodiment explained above in that corrugated flat tubes 3 and spacer strips 8 are used with circular cylindrical batteries 7 and in that both the coolant supply line 1 and the coolant discharge line 2 are arranged on the same side of the flat tubes 3.

[0050] FIG. 7 shows schematically a detail of another embodiment of a cooling module comprising a coolant supply line 1, a coolant discharge line 2, a plurality of flat tubes 3, and spacer strips 8. In the embodiment of FIGS. 6 and 7, the extensions 11 of the spacer strips 8 have openings formed as through holes through which the coolant supply line 1 and the coolant discharge line 2, respectively, pass. In this respect it is to be noted that the connectors 6 may themselves form the coolant supply line 1 and the coolant discharge line 2 without additional line segments.

[0051] In the embodiment of FIG. 7, connectors 6 arranged at one of the ends of the flat tubes 3 are stuck into the line segments of the coolant supply line 1 and the coolant discharge line 2, respectively. Hence, the line segments of the coolant supply line 1 and the coolant supply line 2 are female parts of a push-fit or plug-connection, whereas the connectors 6 are male parts of that push-fit or plug-in connection.

[0052] FIG. 8 shows a schematic cross-section of the connection of two segments of the coolant supply line 1 or the coolant supply line 2, respectively. As can be seen, connectors 6 of neighbouring flat tubes are stuck into a segment of the coolant supply line 1 (or the coolant discharge line 2 which may be formed in the same way). This segment surrounds the connectors 6 and carries on an inside an annular seal 10. The annular seals 10 each surround one of the connectors 6 and press against it.

[0053] In the embodiment shown in FIG. 8, a separate annular seal 10 is arranged inside the line segments for each connector 6. Alternatively, the annular seal 10 may also be single piece that presses against both connectors 6.

[0054] FIG. 9 shows a detail of another embodiment of a cooling module for batteries of an electric or hybrid vehicle. This embodiment differs from the embodiment of FIGS. 1 to 5 in that the supply line and the discharge line are formed from connectors of adjacent flat tubes alone. That is the connectors alone form segments of the supply line as well as the discharge line and there are no separate tube segments attached to the connectors as shown, e.g., in FIG. 4.

[0055] As shown in FIG. 9, line segments of the supply line and the discharge line are formed by two connectors 6a, 6b wherein one of these connectors 6a is a male connector and the other connector 6b a female connector. The male connector 6a penetrates into the female connector 6b. An annular seal 10, e.g., an O-ring may be arranged between the male connector 6a and the female connector 6b, for example, in a groove of the male connector 6a.

[0056] FIG. 10 shows an embodiment of a spacer strip 8 which may be used for system as shown in FIGS. 7 and 8. The spacer strip 8 comprises an intermittent groove 13. The function of this groove 13 is take up any excess amount of adhesive that is applied to bonding surfaces 14 on both lateral sides of the groove 13. As can be seen in FIG. 10, the groove 13 is present only in valleys of the corrugated spacer strip 8. In sections of the spacer strip 8 that form hills the groove is discontinued. That is because cylindrical batteries are placed in the valleys and fixed to the spacer strip 8 in these valleys by an adhesive. As batteries or battery cells are fixed to both sides of the spacer strip, the intermittent groove 13 is on both sides of the spacer strip. Where the groove 13 ends on one side of the spacer strip 8 it begins on the other side of the spacer strip as a hill on one side of the spacer strip 8 is a valley on the opposite side.

[0057] The bonding surfaces 14 to be fixed by means of an adhesive to batteries or battery cells alternate in longitudinal direction of the spacer strips 8 with surfaces 17 not intended for contacting batteries. These surfaces 17 may be recessed surfaces (not shown). The bonding surfaces 14 are in the valleys of the corrugated spacer strip 8 and the surfaces 17 not intended for contacting batteries are on the hills of the corrugated spacer strip 8. Where the spacer strip 8 has a surface 17 on one side, there is a bonding surface 14 on the opposite side of the spacer strip 8, and vice versa.

[0058] Recessed surfaces alternating with bonding surfaces 14 may locally reduce the thickness of the spacer strip 8 and thereby reduce weight. Any recessed surfaces may be provided with webs in order to improve mechanical stability.

[0059] In their extensions 11, the spacer strips 8 have openings through which line segments 15 of the coolant supply line or the coolant discharge line respectively pass. The openings are through holes into which line segments 15 are inserted. An embodiment of such a line segment 15 is shown in FIGS. 12 and 13.

[0060] FIG. 11 shows a cross-section of a detail of FIG. 10 illustrating how the line segments 15 may be fixed to the spacer strips 8. The line segments 15 are fixed to the spacer strips 8 by means of a clipped or snap-locked connection. The line segments 15 have an abutment ring 19 that abuts the spacer strip 8 when the line segment 15 is inserted into opening 16 of a spacer strip 8. The line segments 15 also comprise snap-in hooks 20, which may extend from the abutment ring 19, for example. The openings of the spacer strips 8 have circumferential recesses for accommodating the snap-in hooks 20. In this way an easy assembly of the system is facilitated.

[0061] While exemplary embodiments have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of this disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

LIST OF REFERENCE SYMBOLS

[0062] 1 Coolant supply line [0063] 2 Coolant discharge line [0064] 3 Flat tube [0065] 5 End piece [0066] 6 Connector [0067] 7 batteries [0068] 8 Spacer strip [0069] 10 Annular seal [0070] 11 Extension [0071] 12 Seal [0072] 13 Groove [0073] 14 Bonding surface [0074] 15 Line segment [0075] 17 Recessed surface [0076] 19 Abutment ring [0077] 20 Snap-in hook