Method for producing a plate-shaped heat exchanger, plate-shaped heat exchanger, and assembly comprising plate-shaped heat exchangers

Abstract

Disclosed is a method for producing a plate-shaped heat exchanger for batteries or converters for generating electricity, to a plate-shaped heat exchanger for batteries or converters for generating electricity, and to an assembly of plate-shaped heat exchangers and converter or battery cells. A plate-shaped heat exchanger includes two frame parts, which peripherally surround one profiled heat-conducting element each, wherein the profiles of the profiled heat-conducting elements form channels in the connected state of the frame parts, through which channels a fluid can be conducted. In the connected state, the frame parts form at least two supply channels for feeding and leading away of fluid, from which supply channels openings extend to the channels of the profiled heat-conducting elements. The frame parts have at least one connection for the feeding and leading away of fluid for each supply channel, which connection can be connected to a connection of a frame part of a further heat exchanger.

Claims

1. A plate-shape heat exchanger for batteries or converters for power generation, consisting of two interconnected frame parts of plastics material, which each surround a profiled thermal conduction element by encircling and which are connected with the profiled thermal conduction elements at the outer circumference thereof, wherein the profiles of the profiled thermal conduction elements in the connected state of the frame parts face each other and form channels between the connected profiled thermal conduction elements through which a fluid can be fed and wherein the frame parts in the connected state form at least two supply channels for the feed and/or discharge of fluid, from which openings to the channels of the profiled thermal conduction elements extend, wherein the frame parts each have for each supply channel at least one connection for the feed and/or discharge of fluid, which connection is connectible with a connection of a frame part of a further heat exchanger, wherein the connections of the frame parts of a heat exchanger are so constructed that the connections of a first frame part of the heat exchanger are connectible with the connections of a second frame part of the further heat exchanger.

2. The plate-shaped heat exchanger according to claim 1, wherein the connection of a first frame part is insertable into the connection of a second frame part.

3. The plate-shaped heat exchanger according to claim 2, wherein the connection of the first frame part has a notch which is surrounded by a sealing ring.

4. The plate-shaped heat exchanger according to claim 1, wherein the thermal conduction elements are formed of metal or graphite.

5. The plate-shaped heat exchanger according to claim 1, wherein the first or second frame part has support webs for electrical contacts of converter cells or battery cells.

6. The plate-shaped heat exchanger according to claim 1, wherein the first or second frame part has at least one mounting pin.

7. An assembly comprising a plurality of plate-shaped heat exchangers and converter or battery cells, wherein the converter or battery cells are arranged in a stack and a respective plate-shaped heat exchanger of claim 1 is arranged between the converter or battery cells, wherein the plate-shaped heat exchangers are connected together by way of the connections and are connected with a device for the feed and discharge of fluid.

8. The assembly according to claim 7, wherein the device is constructed for cooling and circulating the fluid.

9. The assembly according to claim 7, wherein the converter cells or battery cells are electrically connected together by an isolating device.

10. The assembly according to claim 7, wherein the assembly can be extended by at least one plate-shaped heat exchanger and by at least one converter cell or battery cell.

11. The assembly according to claim 7, comprising a monitoring unit which is constructed for the purpose of carrying out at least monitoring of state and/or monitoring of temperature of the converter cells or battery cells.

12. The assembly according to claim 11, comprising an isolating device which depending on the states determined by the monitoring unit electrically isolates at least one converter cell or battery cell if the states exceed predeterminable limits.

13. The assembly according to claim 12, wherein the isolating device is a pyrotechnically operating device or an electrically, magnetically or mechanically operating device.

14. A method of producing a plate-shaped heat exchanger for batteries or converters for power generation as claimed in claim 1, comprising the steps of: injection-moulding around a first profiled thermal conduction element at the outer circumference thereof with a plastics material so as to form a first frame part with formation of two supply channel halves, from which depressions extend to the profiled thermal conduction element, and a respective connection for each supply channel half, injection-moulding around a second profiled thermal conduction element at the outer circumference thereof with a plastics material so as to form a second frame part with formation of two supply channel halves, from which depressions extend to the profiled thermal conduction element, and a respective connection for each supply channel half, connecting the first frame part with the second frame part, wherein the first frame part is brought into conjunction with the second frame part in such a way that the profiles of the profiled thermal conduction elements face towards and bear against one another and the supply channel halves of the first and second frame parts form supply channels and the depressions form openings from the supply channels to the channels formed by the profiles of the profiled thermal conduction elements, wherein the connections of the first and second frame parts are so constructed that the connections of the first frame part of the heat exchanger can be connected with the connections of a second frame part of a further heat exchanger.

15. The method according to claim 14, wherein the connecting of the plastics material of the first frame part with the plastics material of the second frame part is carried out by way of welding.

16. The method according to claim 14, wherein the connecting of the profiled thermal conduction elements is carried out by adhesion under applied heat.

17. The method according to claim 15, wherein the welding is carried out by heating plates or infrared radiation welding.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further objects, features, advantages and possibilities of use are evident from the following description of embodiments, which are not be understood as restrictive, with reference to the associated drawings. In that case, all described and/or pictorially illustrated features by themselves or in any desired combination form the subject disclosed herein, regardless of the grouping thereof in the claims or the dependencies thereof. The sizes and proportions of the components shown in the figures in that regard are not necessarily to scale. In forms of embodiment to be realised, they can differ from those illustrated.

(2) In the drawings:

(3) FIG. 1 shows a perspective view of two thermal conduction elements;

(4) FIG. 2 shows a perspective view of two plastics material frames;

(5) FIG. 3 shows a perspective view of two plastics material frames with two thermal conduction elements;

(6) FIG. 4 shows a perspective view of a plate-shaped heat exchanger;

(7) FIG. 5 shows a further perspective view of a plate-shaped heat exchanger;

(8) FIG. 6 shows a sectional view of a plate-shaped heat exchanger;

(9) FIG. 7 shows a partly sectioned view of a plate-shaped heat exchanger;

(10) FIG. 8 shows a sectional view of two connected plate-shaped heat exchangers;

(11) FIG. 9 shows a sectional view of two plate-shaped heat exchangers and adjoining battery cells;

(12) FIG. 10 shows a further view of two plate-shaped heat exchangers and adjoining battery cells in the region of the contacts; and

(13) FIG. 11 shows a perspective schematic view of an assembly of battery cells and plate-shaped heat exchangers.

DETAILED DESCRIPTION OF THE DRAWINGS

(14) FIG. 1 shows a perspective view of two thermal conduction elements 16 and 18. The first thermal conduction element 16 and the second thermal conduction element 18 each have a profile 22 which forms so-called half channels substantially in longitudinal direction. These half channels of the first thermal conduction element 16 and of the second thermal conduction element 18 form, in the joined-together state of the two thermal conduction elements 16, 18, channels 46 as indicated in more detail later.

(15) The first thermal conduction element 16 and the second thermal conduction element 18 consist of a thermally conductive metal. However, the first thermal conduction element 16 and the second thermal conduction element 18 can also consist of graphite, which has a higher thermal conductivity than, for example, copper.

(16) A plastics material is injection-moulded around the circumferential edge 20 of the first thermal conduction element 16 and the second thermal conduction element 18 so as to form a first frame part 12 and a second frame part 14. For that purpose, the first thermal conduction element 16 and the second thermal conduction element 18 are each placed in an appropriate injection-moulding mould and subsequently a suitable plastics material is injected around these.

(17) FIG. 2 shows a perspective view of two plastics material frames 24 and 26, which are injection-moulded and constructed on the circumferential edge 20 of the first thermal conduction element 16 and of the second thermal conduction element 18. In FIG. 2 the first plastics material frame 24 and the second plastics material frame 26 are illustrated without the first thermal conduction element 16 and the second thermal conduction element 18. However, in the case of production of the first frame part 12 and the second frame part 14 for a heat exchanger 10 there is no separate production of the first and second plastics material frames 24, 26 without the thermal conduction elements 16 and 18. As already indicated, the first plastics material frame 24 and the second plastics material frame 26 are not produced separately from the thermal conduction elements 16, 18, but are injection-moulded on these. However, FIG. 2 shows the first plastics material frame 24 and the second plastics material frame 26 separately from the first and second thermal conduction elements 16, 18.

(18) The first plastics material frame 24 and the second plastics material frame 26 are of substantially identical construction, but the second plastics material frame 26 additionally has support webs 34 and mounting pins 36. In addition, the first plastics material frame 24 and the second plastics material frame 26 differ in the connections 38 and 40, as described more specifically further below. The first plastics material frame 24 and the second plastics material frame 26 otherwise correspond with one another, just as the first thermal conduction element 16 is constructed substantially the same as the second thermal conduction element 18. The support webs 34 of the second plastics material frame serve as a support surface for contacts 52 for battery cells 50, in which case the contacts 52 rest on the support webs 34 in such a way that easy contact-making with the battery cells 50 is possible.

(19) The first plastics material frame 24 and the second plastics material frame 26 have depressions 28. The depressions 28 are constructed so that they substantially correspond with the half channels formed by the profile 22 of the first thermal conduction element 16 and the second thermal conduction element 18. The first and second plastics material frames 24, 26 are in addition so constructed that supply channel halves 30 are formed around the circumferential edges 20 of the first and second thermal conduction elements 16, 18. The supply channel halves 30 have a substantially U-shaped or semicircular cross-section, the individual supply channel halves 30 being bounded by webs 32. The first and second plastics material frames 24, 26 are so constructed that the U-shaped or semicircular cross-section is maintained over the entire (peripheral) length of the first and second plastics material frames 24, 26. In the joined-together state, the supply channel halves 30 form supply channels 44 and the depressions 28 of the first and second plastics material frames 24, 26 form openings, through which a fluid passes from the supply channels 44 to the channels 46, which are formed by the first and second thermal conduction elements 16 and 18. The separation by way of the webs 32 ensures that throughflow either from top to bottom or from bottom to top can take place.

(20) FIG. 3 shows a perspective view of two plastics material frames 24, 26 with two thermal conduction elements 16, 18. As apparent from FIG. 3, the depressions 28 are correspondingly arranged in such a way that the depressions 28 bear congruently against the half channels formed by the profile 22. In order to provide congruency of the depressions 28 with the profile 22 of the first and second thermal conduction elements 16 and 18, the injection-moulding moulds for the first frame part 12 and the second frame part 14 are constructed so as to guarantee congruency.

(21) FIG. 4 shows a perspective view of a plate-shaped heat exchanger 10. The first frame part 12 comprises a thermal conduction element 16 and a plastics material frame 24 which is injection-moulded on the thermal conduction element 16 and surrounds the first thermal conduction element 16. In addition, the first frame part 12 has connections 38. By way of the connections 38, the first frame part 12 of a heat exchanger 10 can be connected with a second frame part 14 of a further heat exchanger 10 via the correspondingly constructed connections 40 thereof. In addition, a device (not illustrated in the figures) for the feed of a coolant/fluid can also be connected by way of the connections 38.

(22) FIG. 5 shows a further perspective view of a plate-shaped heat exchanger 10. The second frame part 14 comprises a second thermal conduction element 18 as well as a second plastics material frame 26 surrounding the second thermal conduction element 16 and injection-moulded on the second thermal conduction element 18. The second plastics material frame 26 has, apart from the support webs 34 and the mounting pins 36, connections 40 which are so constructed that the connections 38 of the first frame part 12 can be inserted into the connections 40.

(23) FIG. 6 shows a sectional view of a plate-shaped heat exchanger 10. The plate-shaped heat exchanger 10 comprises a first frame part 12 and a second frame part 14. The first frame part 12 is formed by a first thermal conduction element 16 and a plastics material frame 24 injection-moulded on the first thermal conduction element 16 and surrounding the first thermal conduction element 16. The second frame part 14 comprises a second thermal conduction element 18 as well as a second plastics material frame 26 surrounding the second thermal conduction element 18 and injection-moulded on the second thermal conduction element 18. The first and second frame parts 12 and 14 are connected together by welding, the welding being carried out in the region of the first and second thermal conduction elements 16, 18. The profiles 22 of the first thermal conduction element 16 and the second thermal conduction element 18 are so connected together by way of induction of heat that the half channels of the profiles 22 form channels 46. In addition, fusing together of the plastics materials of the first plastics material frame 24 and the second plastics material frame 26 takes place by way of the heat induction. As a result, supply channels 44, by way of which a fluid flowing through the channels 46 can be fed, are formed. When the fusing of the plastics material of the first plastics material frame 24 to the plastics material of the second plastics material frame 26 takes place, those regions of the plastics material which bear against one another fuse together and connect with one another. Fusing of the webs 32 of the plastics material frame 24 to the corresponding opposite webs 32 of the plastics material frame 26 therefore also takes place.

(24) By way of the depressions 28, which in the joined-together state of the first and second frame parts 12, 14 form openings or again small channels, a fluid can flow from the supply channel 44 via the openings formed by the depressions 28 and via the channels 46 as well as via the opposite openings formed by the depressions 28 to the opposite supply channel 44, the fluid being supplied and passed on by way of the connections 38 and 40.

(25) As can be inferred from FIGS. 4 and 5, the connections 38 and 40 can be arranged to be offset relative to one another. As a result, throughflow of the heat exchanger 10 from top to bottom or from bottom to top takes place depending on the feed of a fluid, in which case there is uniform distribution by way of the channels 46.

(26) The connections 38 and 40 are in addition illustrated in FIG. 6, wherein the connection 38 has a sealing ring 48 received in a correspondingly formed notch 42 (FIG. 8). The connections 38 and 40 are constructed so that the connection 38 of the first frame part 12 can be inserted into the connection 40 of the second frame part 14. A stacked arrangement of heat exchangers 10 adjacent to one another is thereby possible without the heat exchangers needing separate feed lines or arrangements, which in particular require further means or protrude from the assembly from outside, for the supply and discharge of a fluid. The connections 38 and 40 protrude from the heat exchanger 10 by a specific amount. This results in a certain spatial distance between two heat exchangers 10 arranged adjacent to one another. The space thus created serves for reception of battery cells 50 or converter cells. The form of the connections 38 and 40 can, however, also differ from the construction shown in the figures. The design always has to be in accordance with the battery cells 50 or converter cells to be received as well as the rest of the design of the heat exchanger 10.

(27) FIG. 7 shows a partly sectioned view of a plate-shaped heat exchanger 10 in the region of the connections 38 and 40. As can be clearly inferred from FIG. 7, the profiles 22 of the first thermal conduction element 16 and the second thermal conduction element 18 in the joined together state of the first frame part 12 and the second frame part 14 form channels 46. The same applies to the depressions 28 of the first plastics material frame 24 of the first frame part 12 and the depressions 28 of the second plastics material frame 26 of the second frame part 14.

(28) Moreover, supply channels 44 are formed by way of the supply channel halves 30 of the first frame part 12 and the second frame part 14. A sealing ring 48 is placed on the notch 42 of the connection 38 and prevents fluid for cooling being able to escape in the inserted state of the connection 38 in a connection 40.

(29) FIG. 8 shows a sectional view of two connected plate-shaped heat exchangers 10. FIG. 8 clearly shows how the arrangement of heat exchangers 10 is realised. The connection 38 of a first plastics material frame 24 of the first frame part 12 of a heat exchanger 10 is in that case inserted into the connection 40 of a second plastics material frame 26 of the second frame part 14 of the further heat exchanger 10. It is ensured by way of the sealing ring 48 that no coolant or fluid can escape. A battery cell or converter cell, which is to be cooled, is arranged between heat exchangers 10.

(30) FIG. 9 shows a sectional view of two plate-shaped heat exchangers 10 and adjacent battery cells 50 in the region of the contacts 52. The contacts 52 of battery cells 50 are led out of the space between two heat exchangers 10 by way of the support webs 34. A relatively large contact area is provided by way of the design of the support 34 and the supporting of the contacts 52. The battery cells 50 are so arranged between the heat exchangers 10 that they lie between the first thermal conduction element 16 and the second thermal conduction element 18. As illustrated in FIG. 9, the first and second thermal conduction elements 16, 18 are also constructed in such a way that further layers (thermally conductive) are applied on the outer side, i.e. facing the battery cells 50, or, however, the first and second thermal conduction elements 16 and 18 are constructed so that in correspondence with the area of the heat exchanger 10 they protrude as far as the region of the supply channels 44 and are flush therewith.

(31) FIG. 10 shows a further view of two plate-shaped heat exchangers 10 and adjoining battery cells in the region of the contacts 52. In this case, the arrangement of the mounting pins 36 as well as the design of the connection 38 with sealing ring 48 are illustrated to enlarged scale. In addition, FIG. 10 makes it clear that the battery cells 50 bear directly against the heat exchangers 10.

(32) FIG. 11 shows an assembly 60 of battery cells 50 and plate-shaped heat exchangers 10. By virtue of the design of the plate-shaped heat exchangers 10, particularly with the connections 40 and 38, a space-saving arrangement results. Moreover, it is sufficient to feed a fluid for cooling the battery cells 50 to the assembly 60 only to and from a first heat exchanger 10 or a last heat exchanger 10 by way of lines or other devices. The throughflow of the heat exchangers 10 arranged therebetween is realised by way of the connection of the connections 38 and 40. The contacts 52 of the battery cells 50 protrude from the region between two heat exchangers 10 and are laid over the support webs 34 and rest on these for further contact-making. An assembly 60 of that kind can comprise further battery cells 50 and heat exchangers 10. The illustration selected in FIG. 11 is only by way of example and shows a detail of an assembly 60 for, for example, high-power batteries for motor vehicles.

REFERENCE NUMERAL LIST

(33) 10 heat exchanger 12 first frame part 14 second frame part 16 first thermal conduction element 18 second thermal conduction element 20 circumferential edge 22 profile 24 first plastics material frame 26 second plastics material frame 28 depression 30 supply channel halves 32 web 34 support web 36 mounting pin 38 connection 40 connection 42 notch 44 supply channel 46 channel 48 sealing ring 50 battery cell 52 contact 60 assembly