CONNECTOR DEVICE

Abstract

The present invention relates to a connector device suitable for connection between a heat exchange tube with a flat configuration and at least one conduit which can be a liquid coolant feed conduit, a liquid coolant return conduit, or both. The connector device is particularly suitable for heat exchange tubes for heat exchange with battery cells where the free spaces left by the cell cluster are filled with foam. Barrier means which are interposed between the outside of the connector and sealing means established in the attachment with the exchange tube are used in the connector. The barrier means prevent, or at least hinder, the entry of the foam used when manufacturing the battery while allowing the verification of the existence of leakages, for example, in quality control testing.

Claims

1. A connector device suitable for connection between a heat exchange tube with an essentially flat configuration and at least one conduit that is a feed conduit, or a return conduit, or both, for a liquid coolant, the tube showing one or more access openings, wherein the device comprises a shell comprising at least one connection port located on the outside of the shell intended to establish a fluidic connection with the at least one conduit; at least one fluidic connection adapted to establish a fluidic connection with an access opening for accessing the heat exchange tube, wherein the fluidic connection is additionally in fluidic communication with the at least one connection port, and wherein the fluidic connection comprises a sealing means to establish sealing between the fluidic connection and the access opening for accessing the heat exchange tube; wherein said connector device comprises barrier means to at least partially prevent the access of a foamed material from outside the shell to the sealing means, and wherein the barrier means are adapted to allow the exit of fluid if the sealing means leak.

2. The device according to claim 1, wherein the fluidic connection is an inner connection located inside the shell.

3. The device according to claim 1, wherein the barrier means are a perimeter gasket comprising an elastically deformable lip, configured to be supported on a surface on which the passage barrier is established, the lip being arranged in an oblique manner to allow the easy exit of fluid and to hinder the entry of a foamed material.

4. The device according to claim 1, wherein the barrier means are a perimeter gasket comprising a porous material, wherein the pores are intercommunicated.

5. The device according to claim 4, wherein the porous material is elastically deformable.

6. The device according to claim 1, comprising: two connection ports, an inlet connection port and an outlet connection port; two fluidic connections, an outlet fluidic connection and an inlet fluidic connection; the inlet connection port is in fluidic communication with the inlet fluidic connection, and the outlet connection port is in fluidic communication with the outlet fluidic connection; and the inlet fluidic connection is adapted to connect with an access opening for accessing the heat exchange tube for the entry of liquid coolant, and the outlet fluidic connection is adapted to connect with another access opening for accessing the heat exchange tube for the exit or return of the liquid coolant.

7. The device according to claim 6, wherein the shell comprises two couplable parts, a first part and a second part, wherein: once the two parts are coupled, the heat exchange tube is interposed between both parts; the first part intended, in the operating mode, for introducing fluid into the tube, wherein the first part comprises the inlet connection port and the inlet fluidic connection; the second part intended, in the operating mode, for recovering the return fluid from the tube, wherein the second part comprises the outlet connection port and the outlet fluidic connection.

8. The device according to claim 1, wherein the barrier means show a first support region on the shell and a second support configured to be supported on either the tube or the manifold if the connection with the tube is with the intermediation of a manifold, and to be coupled on the tube in the operating mode, the sealing means are housed in a space closed by the barrier means.

9. A heat exchange tube comprising at least one connector device according to claim 1.

10. A heat exchange tube comprising at least one connector device according to claim 7, wherein a first part of the connector device is in fluidic communication with one or more inner channels of the tube to feed an outbound flow; a second part of the connector device is in fluidic communication with one or more inner channels of the tube to receive the return flow; the first part and the second part of the connector device are at one end of the tube according to a longitudinal direction, and at the opposite end of the tube, the one or more inner channels for the outbound flow are in fluidic communication with the one or more channels for the return flow to configure a U-shaped flow.

11. A heat exchange tube comprising at least one connector device according to claim 7, wherein a first part of the connector device is in fluidic communication with one or more inner channels of the tube to feed an outbound flow; a second part of the connector device is in fluidic communication with one or more inner channels of the tube to receive the return flow; the first part and the second part of the connector device are in an intermediate position of the tube according to a longitudinal direction, and at both ends of the tube, the one or more inner channels for the outbound flow are in fluidic communication with the one or more channels for the return flow to configure two U-shaped flows.

12. The heat exchange tube according to claim 10, wherein the inlet fluidic connection and the outlet fluidic connection are oriented towards the same side, according to the direction transverse to the tube such that it is parallel to the dimension establishing the width of the tube.

13. A battery comprising a plurality of cells and exchange tubes for regulating the temperature of the cells, wherein said tubes are heat exchange tubes comprising at least one connector device according to claim 1, and wherein the heat exchange tubes are connected with a heat exchange liquid feeding and recovery means by the at least one connector device.

14. A vehicle comprising at least one battery according to claim 13.

15. A method of assembling a battery comprising a plurality of cells and at least one heat exchange tube for the thermal regulation of the cells, wherein the method comprises the steps of: coupling at least one connector device according to claim 1 to an opening of either an exchange tube or a feed manifold of the tube if the tube has said manifold; carrying out a sealing verification test by means of the following sub-steps: subjecting the attachment between the connector device and the tube, or the manifold of the tube, if there is a manifold, to pressure with a verification fluid, verifying if the barrier means of the connector device show leakage of the verification fluid, if there is no leakage of the verification fluid through the barrier means, emptying the tube and the verification fluid connection device and incorporating the tube with the connector device in thermal contact with one or more cells configuring a battery cell pack housed in a shell, or if there is a leakage of verification fluid, disposing of the tube and connector device assembly by trying a new tube with its connector device; introducing a foaming material into the shell with the cells and the at least one tube connected by means of the connector device and allowing the foam to expand therein.

Description

DESCRIPTION OF THE DRAWINGS

[0083] These and other features and advantages of the invention will become more apparent based on the following detailed description of a preferred embodiment, given only by way of illustrative and non-limiting example, in reference to the attached figures.

[0084] FIG. 1 This figure schematically shows a front view of an embodiment of a heat exchange tube.

[0085] FIG. 2 This figure schematically shows a front view of another embodiment of a heat exchange tube.

[0086] FIG. 3 This figure schematically shows a front view of another embodiment of a heat exchange tube.

[0087] FIG. 4 This figure schematically shows a first embodiment of the connector device, in which the heat exchange tube is shown according to a cross-section and in which the plane of section also sections the connector device to visually access the inside thereof.

[0088] FIG. 5 This figure schematically shows a second embodiment of the connector device with the shell in two parts, in which the heat exchange tube is shown according to a cross-section and in which the plane of section also sections the connector device to visually access the inside thereof.

[0089] FIG. 6 This figure schematically shows barrier means formed by a perimeter gasket with an elastically deformable lip, the surface on which it is supported, and with a partial section to allow observing its configuration.

DETAILED DESCRIPTION OF THE INVENTION

[0090] According to the first inventive aspect, the present invention relates to a connector device suitable for, and more specifically adapted to allow the connection of liquid coolant feed and return conduits with one or more heat exchange tubes from among the tubes arranged between the battery cells of a vehicle so as to ensure that they are at a suitable operating temperature.

[0091] Considering FIG. 1, this figure schematically shows a front view of an embodiment of a heat exchange tube (1).

[0092] The tube (1) shown has an essentially flat configuration, which means that its shape extends mainly in two dimensions although it can adopt a winding path in the longitudinal direction. Most commonly, this path is corrugated to allow establishing the largest area of contact possible with the cylindrical-shaped cells. Therefore, FIG. 1 to 3, which are schematic examples, must be interpreted generally, understanding that what is important is its structure and that it can adopt this corrugated shape as an embodiment.

[0093] In the embodiment of FIG. 1, the heat exchange tube (1) has an inner structure formed by a plurality of channels (1.3) arranged parallel to one another and extending longitudinally. This channel structure allows establishing a guided flow along the entire length of the tube (1) and allows, for example, the flow rate through the entire section of the tube (1) to be about the same.

[0094] For example, tubes of this type are manufactured by means of extrusion, for example in aluminum, and the corrugated shape is manufactured by stamping the extruded tube (1).

[0095] The left side of the figure shows a circle representing a non-through opening which provides access to all the inner channels of the heat exchange tube (1) through one of the faces of the tube (1). For example, a milling operation on one of the faces of the tube (1) allows removing the material of the disk forming the wall of the tube (1) and, by proceeding further with this milling operation, the material forming the separation wall between the inner channels (1.3) in this area would be removed to therefore form a chamber that performs the function of a manifold for the feeding or exit of the liquid coolant.

[0096] Other equivalent forms make a through perforation and delimit one of the faces, for example, by means of a part that ensures sealing so that a fluid entering or exiting through the opening (1.1) is transferred entirely to/from the inside of the inner channels (1.3) of the tube (1)

[0097] FIG. 2 schematically shows a heat exchange tube (1) in which two groups of channels (1.3) have been distinguished, a first group of channels (1.3) shown in the top part and a second group of channels (1.3) shown in the bottom part and separated from the first group of channels (1.3) by the wall separating the two adjacent channels (1.3). This separation has been schematically depicted with a discontinuous line. Both this discontinuous line and the discontinuous lines defining the separation walls of the channels (1.3) identify that they are found on the inside, and therefore not parts that can be seen from the outside.

[0098] In this embodiment, one of the openings (1.1), the upper opening (1.1), is located on the visible side, and the other opening (1.2) is located on the other side of the heat exchange tube (1), hence it is also depicted in discontinuous lines.

[0099] This configuration allows having the entire space given by the height of the heat exchange tube (1). Height is understood as the orientation in the figure and it is therefore the width of the flat tube (1). The third dimension, other than the length and width of the tube (1), will be considered as the thickness of the heat exchange tube (1).

[0100] According to the configuration of the tube (1) shown in FIG. 1, the flow is an outbound flow or an inbound flow, but not both at the same time. That is, the flow enters through the opening (1.1) and exits in another location of the tube (1) through another opening (1.2), or vice versa.

[0101] According to the configuration of the tube (1) shown in FIG. 2, the same tube (1) can transport the outbound flow in one group of channels (1.3) and the return flow in another group of channels (1.3). In these cases, the tube (1) has at one end a manifold which allows transferring the fluid from the first group of channels (1.3) to the second group of channels (1.3) and is designated as a U-shaped flow.

[0102] FIG. 3 schematically shows another embodiment of the heat exchange tube (1) wherein the introduction or extraction of the liquid coolant is performed through two manifolds (A) accessing the channels (1.3) through the end of the heat exchange tube (1). The advantage of this configuration is that it does not require

[0103] machining operations on an extruded tube and the addition of additional parts, for example, two stamped metal sheets, is sufficient to configure the manifolds (A).

[0104] Although not depicted in FIGS. 1 to 3, this specific way of using an intermediate manifold is applicable to a tube such as the one of FIG. 1 in which there is only an outbound or return flow.

[0105] FIG. 3 also shows that to the left side of the manifolds (A) the heat exchange tube (1) is prolonged in the same manner as it to the right side, always using the terms right, left, up, and down to refer to the positions shown in the figures.

[0106] In this way, the manifold (a) may be located not only at the end of the heat exchange tube (1) but also at an intermediate point of the heat exchange tube, for example, at a central point according to the longitudinal direction. This allows the liquid coolant to be fed and removed at an intermediate point. The liquid coolant is transported to the two opposite ends of the heat exchange tube (1) through a group of channels (1.3) and, returns to the same intermediate point through the other group of channels (1.3). Notwithstanding the foregoing, the entry of the liquid coolant and the exit of the return flow of the liquid coolant can also be at different points according to the longitudinal direction.

[0107] It should be clarified that the longitudinal direction in all the cases described based on FIGS. 1 to 3 is the direction shown to be horizontal.

[0108] All the described tubes (1) are tubes (1) suitable for the described connector devices.

[0109] FIG. 4 schematically shows a first embodiment of the connector device.

[0110] On the right side, a striped rectangle depicts the section of the heat exchange tube (1) with a flat configuration accessed through an opening (1.1) which, according to the orientation in the figure, is located on the face of the heat exchange tube (1) located on the left side. It is the opening (1.1) through which the heat exchange tube (1) in this embodiment will be fed.

[0111] The feed comes from a conduit (C) shown with a thick black arrow indicating the entry of the liquid coolant. The conduit (C) is connected to a connection port (2.1.1) in the form of a spigot or a tubular body which, in this embodiment, is inserted into the conduit (C).

[0112] The connection port (2.1.1) emerges from a shell (2) formed in this example by a part (2.1) and having a fluidic connection (2.1.2) intended for connection with the opening (1.1) of the heat exchange tube (1).

[0113] The fluidic connection (2.1.2) shows sealing means (4) intended for preventing leakages in the fluid transfer between an inner conduction of the shell (2) and the inside of the heat exchange tube (1).

[0114] The inner conduction of the shell (2) is schematically shown with a discontinuous arrow and this inner conduction is responsible for putting the connection port (2.1.1) and the fluidic connection (2.1.2) in fluidic communication. In this way, the fluid coming from the conduit (C) is transferred without leakage to the heat exchange tube (1).

[0115] The same FIG. 4 shows the shell (2), and in this particular example the outer region of the inner conduction of the shell (2) with a seat on which the barrier means (3) are supported. In this embodiment, these barrier means (3) are formed by an annular part made of a porous material and supported both on the seat of the shell (2) and on the outer surface of the heat exchange tube (1) such that the sealing means are housed therein.

[0116] If the part (2.1) forming the shell (2), which is not leak-tight, allows the entry of foam during the assembly of the battery to protect its cells, this foam will not have direct access to the sealing means (4) since the barrier means (3) are interposed.

[0117] In contrast, if the sealing means fail in a quality control test to verify the sealing between the fluidic connection (2.1.2) and the heat exchange tube (1), the leaked fluid meets the barrier means (3) from the inside and the leaked fluid is capable of coming out through the porous material, demonstrating a failed sealing.

[0118] The same occurs when the barrier means (3) are formed by a perimeter gasket comprising an elastically deformable lip such as that shown in FIG. 6 and will be described below.

[0119] FIG. 5 schematically shows another embodiment applicable to a tube (1), wherein one or more inner channels (1.3) are intended for an outbound flow and one or more inner channels (1.3) are intended for a return flow, as shown in FIGS. 2 and 3, for example.

[0120] In this embodiment, the shell (2) is formed by two parts, a first part (2.1) located on one side of the heat exchange tube (1), for example the left side as shown in the figure, and a second part (2.2) located on the other side of the heat exchange tube (1), now on the right side as shown in the figure.

[0121] In this embodiment, the opening (1.1) into which the liquid coolant is introduced is located in the top part and accessible from the left, always following the orientation shown in FIG. 5 and, the exit of the liquid coolant through another opening (1.2) is located in the bottom part and accessible from the right.

[0122] In this way, the first part (2.1) of the shell (2) is located on one side of the tube (1) to provide liquid coolant to the tube (1) and the second part (2.2) of the shell (2) is located on the opposite side of the tube (1) to remove the return liquid coolant flow, as shown by the thick black arrows located in the feed and return conduits (C).

[0123] The first part (2.1) is as described in the embodiment shown in FIG. 4, only now the size of the shell (2) is shown to be larger so as to match the size of the second part (2.2) located on the right side and must reach the lower position, now on the other side according to the direction indicated by the width of the heat exchange tube (1) or vertical direction according to the figure where the opening (1.2) for the return flow is located.

[0124] This second part (2.2) is also configured with a connection port (2.2.1) and a fluidic connection (2.2.2) intended for leak-tight connection on the second opening (1.2), the port (2.2.1), and the connection (2.2.2) fluidically communicated through an inner conduction which is now somewhat longer than that of the first part (2.1). The configuration of the sealing means (4) and the barrier means (3) are as described for the first part (2.1), so such descriptions also apply to this second part (2.2).

[0125] This opposing configuration, the first part (2.1) on one side of the heat exchange tube (1) with a flat configuration and the second part (2.2) on the other side of the heat exchange tube (1), allows both parts to be able to be mechanically linked to one another, leaving the heat exchange tube (1) interposed between them. This mechanical linkage, not visually shown in FIG. 5, can be formed by a clipped attachment or a screwed attachment, only as examples of methods for establishing a mechanical linkage.

[0126] This configuration in which the two parts (2.1, 2.2) are attached to one another, leaving the exchange tube (1) located between them, allows the sealing means (4) and the barrier means (3) to exert force on the tube (1) or an intermediate manifold, if a manifold is used as described in FIG. 3, in order to perform the respective function thereof given that the parts (2.1, 2.2) of the shell (2) serve as a support as a result of attachment with the opposite part.

[0127] This configuration also prevents the need to establish specific attachment means in the exchange tube (1), with it being sufficient for the two parts (2.1, 2.2) to be designed for attachment to one another leaving the tube (1) interposed.

[0128] This FIG. 5 describes an embodiment in which the connection ports (2.1.1, 2.2.1) of the two parts (2.1, 2.2) are located on the same side considering the direction established by the width of the tube (1), that is, according to the vertical direction following the direction shown in FIG. 5. However, an alternative example provides a connection port (2.1.1) oriented to one side according to the direction established by the width of the tube (1) and the other connection port (2.2.1) oriented in the opposite direction, also according to the direction established by the width of the tube (1).

[0129] These examples correspond to a tube (1) as shown in FIG. 2 or 3 in which the inlet and outlet openings (1.1, 1.2) are located at the same point according to the longitudinal direction of the tube (1).

[0130] Any of the described examples in which there are two openings, an inlet opening (1.1) and an outlet opening (1.2), is also in accordance with an embodiment of the first inventive aspect when both openings (1.1, 1.2) are located at different points and spaced apart according to the longitudinal direction.

[0131] In FIG. 5, the two parts (2.1, 2.2) are located on different faces of the tube (1), that is, they are shown on the left and right sides. Alternatively, the inlet and outlet openings (1.1, 1.2) are located on the same side or face of the tube (1), for example, in an orientation of the tube (1) as shown in FIG. 5, they will be located on either the left side or the right side. In this case, the openings (1.1, 1.2) will preferably be located at different points and spaced apart according to the longitudinal direction as indicated in the preceding paragraph.

[0132] FIG. 6 schematically shows the structure of the barrier means formed by a perimeter gasket comprising an elastically deformable lip. In this example, the perimeter gasket follows a circular path, although it can follow a path, for example, a closed path, adapted to the enclosure to be protected with the barrier means (3).

[0133] FIG. 6 shows, on the left side, the half of the perimeter gasket that is not sectioned and, on the right side, the half sectioned according to a plane parallel to the plane of the paper on which it is depicted.

[0134] The right-side section only depicts a segment of the part of the shell (2) which provides a seat, in this case a staggered seat, with a first striped portion, and the section of the perimeter gasket which shows an oblique lip supported at a point (T) or contact region, which point, according to the section, is located on a surface on which a barrier is established, in this case the surface is the outer surface of the heat exchange tube (1).

[0135] The oblique lip shows an inclination such that its root is located inwardly towards the inner part to be protected, and its end edge, the one supported on the surface on which the closure is established, the heat exchange tube (1), is located in the outermost part.

[0136] With this configuration, an external pressure P2, exerted by the foam from the outer side during its expansion phase, for example, tends to exert a force on the support surface, favoring a force on the same upper surface, and therefore increasing the capacity for closing or even sealing the attachment.

[0137] In contrast, a pressure P1 exerted from the inside, which would be the case of an overpressure due to the leakage of fluid in a sealing test, would cause a force that would tend to lead to the bending of the lip, separating from the surface on which it is supported, allowing the release of the fluid.