Abstract
A heat exchange module for an energy storage module, having a module housing for heat-transferring contact with an energy storage module; at least one operating medium channel for an operating fluid for heat transport; and at least one fluid connection for at least one external line for the operating fluid of the operating medium channel. There is formed by the at least one operating medium channel at least one receiving opening with a predetermined cross section in a channelward extension of the operating medium channel, in which a plug with a shape filling the predetermined cross section of the receiving opening is received such that the receiving opening is bonded thereto in a fluid-tight manner. With the heat exchange module, efficient use is made of a structural space, while the heat exchange module at the same time is able to be manufactured at low cost.
Claims
1. A heat exchange module for an energy storage module, said heat exchange module comprising: a unitary module housing configured to maintain heat-transferring contact with an energy storage module, the unitary module housing including module walls defining a module interior; at least one operating medium channel disposed between the walls of the unitary module housing and within the module interior for receiving an operating fluid for heat transport; at least one fluid connection for at least one external line for the operating fluid of the operating medium channel; at least one receiving opening formed by the at least one operating medium channel and having a predetermined cross section in a channelward extension of the operating medium channel, the at least one receiving opening residing within the module interior and being defined by the walls of unitary module housing; and a plug positioned in the at least one receiving opening that is defined by the module walls, and the plug having a shape that fills the predetermined cross section of the at least one receiving opening such that the receiving opening is bonded thereto in a fluid-tight manner.
2. The heat exchange module as claimed in claim 1, wherein the plug comprises said at least one fluid connection.
3. The heat exchange module as claimed in claim 1, wherein an outer wall of a channel bend is formed by the plug.
4. The heat exchange module as claimed in claim 1, wherein the plug is bonded in a fluid-tight manner to the receiving opening by at least one of the following material bonding methods: friction stir welding; laser welding; gas-shielded welding; and/or adhesion.
5. The heat exchange module as claimed in claim 1, wherein the module housing comprises a receiving chamber for an energy storage module, which receiving chamber is disposed adjacent to the operating medium channel.
6. The heat exchange module as claimed in claim 1, wherein the module housing is terminated at an outer side by the plug in a manner flush with the receiving opening of the operating medium channel, or the plug is received in the receiving channel in a manner recessed inward with respect to the channel.
7. In a heat exchange module for an energy storage module, said heat exchange module including (i) a unitary module housing configured to maintain heat-transferring contact with an energy storage module, the unitary module housing including module walls defining a module interior, (ii) at least one operating medium channel disposed between the walls of the unitary module housing and within the module interior for receiving an operating fluid for heat transport; (iii) at least one fluid connection for at least one external line for the operating fluid of the operating medium channel, (iv) at least one receiving opening formed by the at least one operating medium channel and having a predetermined cross section in a channelward extension of the operating medium channel, the at least one receiving opening residing within the module interior and being defined by the walls of unitary module housing, and (v) a plug positioned in the at least one receiving opening that is defined by the module walls, and the plug having a shape that fills the predetermined cross section of the at least one receiving opening such that the receiving opening is bonded thereto in a fluid-tight manner, a production method for the heat exchange module, said method comprising the following steps: a. providing the module housing and the at least one plug; b. inserting the at least one plug into the corresponding receiving opening; and c. bonding the plug in a fluid-tight manner to the receiving opening.
8. The production method as claimed in claim 7, wherein in a step d., the at least one fluid connection is formed either before step b., or after step c.
9. The production method as claimed in claim 7, wherein before step b., in a step e., a channel bend in the module housing is prepared in that a channel-separating web is shortened at an inner side of the channel bend in the insertion direction of the corresponding plug.
10. The production method as claimed in claim 7, wherein before step b., in step f., the receiving opening is adapted to the plug.
11. The heat exchange module as claimed in claim 1, wherein the plug is positioned between the module walls.
12. The heat exchange module as claimed in claim 1, wherein the plug is positioned entirely within the unitary housing.
13. The heat exchange module as claimed in claim 1, wherein the plug does not protrude outside of the unitary housing.
14. The heat exchange module as claimed in claim 1, further comprising another operating medium channel disposed between the walls of the unitary module housing and within the module interior, and another plug that is positioned within the receiving opening of said another operating medium channel.
15. The heat exchange module as claimed in claim 1, wherein one of the walls of the unitary module housing is positioned between the two walls forming the at least one operating medium channel, wherein said one of the walls is shortened relative to said two walls.
16. The heat exchange module as claimed in claim 15, wherein the plug abuts against said one of the walls.
17. The heat exchange module as claimed in claim 15, wherein an intermediate fluid channel is formed between the plug and said one of the walls.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The above-described invention will be discussed in detail below against the relevant technical background with reference to the associated drawings, which show preferred refinements.
(2) The invention is not in any way restricted by the purely schematic drawings, and it should be noted that the drawings are not to scale and are not suitable for defining size ratios. In the drawings:
(3) FIG. 1 shows a heat exchange module in a face-side plan view;
(4) FIG. 2 shows a detail of the heat exchange module as per FIG. 1 in the sectional view A-A;
(5) FIG. 3 shows a detail of the heat exchange module in an alternative embodiment in a view corresponding to section A-A in FIG. 1;
(6) FIG. 4 shows a flow diagram of a production method for a heat exchange module; and
(7) FIG. 5 shows a motor vehicle with a heat exchange module.
DETAILED DESCRIPTION OF THE INVENTION
(8) FIG. 1 shows a heat exchange module 1 in a front view, wherein the module housing 3 thereof is produced for example by means of extrusion. The module housing 3 comprises a receiving chamber 11 (optionally integrated in one piece in this case), which is configured for receiving an energy storage module 2. Above the receiving chamber 11 according to the illustration, there are formed receiving openings 7 in a channelward extension of the channel sections (cf. FIG. 2), in this case in the form of two elongate holes, which are produced for example by means of milling. The two receiving openings 7 are separated by means of a channel-separating web 12. The channel-separating web 12 is (optionally) formed here in one piece with the module housing 3. In the receiving openings 7, there are inserted in each case one plug 8 with a corresponding shape, such that the plug 8 completely fills the predetermined cross section of the receiving opening 7. Preferably, the plugs 8 are received with play in the in each case corresponding receiving opening 7. In order, then, to bond the plugs 8 to the receiving openings 7 and to terminate them in a fluid-tight manner, use is made in this embodiment of friction stir welding as material bonding method. For this purpose, a friction stir pin 15 travels in a friction stir direction 16, from left to right according to the illustration in this case, over the face side (arranged in the plane of the page) of the heat exchange module 1. The kinetic energy is converted into heat, and, at the boundary surfaces of the plugs 8 (and preferably of the receiving openings 7), the material is melted and a materially bonded and reliably fluid-tight bond between the inserted plug 8 and the receiving opening 7 is thereby produced. Furthermore, the plug 8 arranged on the left according to the illustration comprises a fluid connection 5 (optionally circular in this case), which is configured for introduction and/or discharge of the operating fluid and is connected to an external line 6 (cf. FIG. 2 and FIG. 3). Furthermore, a section plane A-A corresponding to the sectional view in FIG. 2 and FIG. 3, with FIG. 3 showing an alternative embodiment, is drawn here.
(9) FIG. 2 shows a detail of the heat exchange module 1 as per FIG. 1 in the sectional view A-A. Here, it can be clearly seen that, above the left-hand plug 8 of the heat exchange module 1 according to the illustration, an operating medium channel 4 is formed and, above the right-hand plug 8 according to the illustration, the operating medium channel 4 forms a channel bend 10. In this embodiment, an operating medium channel 4 is formed with (in this case, schematically, three) channel sections arranged parallel to one another. Here, it can be seen that the receiving openings 7 are formed in the channelward extension, that is to say in this case in the extension of the orientation of the channel sections which is parallel to the channel-separating webs 12. For example, the fluid connection 5 is an inlet and, on the opposite face side (outside the detail shown) at the channel section on the far right according to the illustration, a further fluid connection is formed as an outlet for the operating fluid, or vice versa. In such an embodiment, the module housing 3 therefore comprises a single operating medium channel 4. Alternatively, a plurality of operating medium channels 4 with in each case one inlet and one outlet, that is to say two fluid connections 5, are formed. In the embodiment shown, the channel section on the far left and the middle channel section are separated fluidically from one another by means of a channel-separating web 12, and the middle channel section and the channel section on the far right are separated fluidically from one another by means of a further channel-separating web 12 (over the predetermined length, that is to say as far as a channel bend 10). The channel bend 10 shown in this detail between the middle channel section and the right-hand channel section is in this case formed so as to be set back (away from the plug 8), for example by means of milling of the right-hand channel-separating web 12. Here, the right-hand plug 8 according to the illustration simultaneously forms the outer wall 9 for the illustrated channel bend 10. For example, the cross sections of the receiving openings 7 formed in the channelward extension are identical to the cross sections of the respective channel section, wherein the right-hand plug 8 according to the illustration overlaps the corresponding channel-separating web 12 of the channel bend 10. A stepless transition between the channel section and the receiving opening 7 is advantageous for example in the case of the module housing 3 being manufactured by means of extrusion, wherein no reworking of the receiving openings 7 is necessary. Here, the plugs 8 are inserted into the receiving openings 7 of the module housing 3 in each case in an insertion direction 13 (from bottom to top according to the illustration). The insertion direction 13 is oriented channelward. Subsequently, the plugs 8, in the respective receiving opening 7, are bonded in a materially bonded and fluid-tight manner to the module housing 3 by means of friction stir welding. Here, a termination of the plugs 8 with respect to the module housing 3 that is flush channelward or with the face surface of the module housing 3 is (optionally) formed such that, in relation to a (predetermined) structural depth of the plug 8 in the (channelward) insertion direction 13, an overall structural length of the heat exchange module 1 is minimal with a long length of the operating medium channel 4. It should be pointed out at this juncture that the structural depth of the plugs 8 is significantly less than in conventional embodiments with connecting pieces pressed in (for example in the insertion direction 13). Furthermore, the fluid connection 5 in the left-hand plug 8 is shown here, this being connected here, preferably in a water-tight manner, to an external line 6. The fluid connection 5 is produced for example by means of subsequent drilling.
(10) FIG. 3 shows a detail of a heat exchange module 1 in an alternative embodiment in a sectional view A-A as per FIG. 3. Below, the differences illustrated here are described and, furthermore, reference is made to the above description with regard to the embodiment as per FIG. 1 and FIG. 2. By contrast to FIG. 2, in the embodiment shown, only one receiving opening 7 is formed in the module housing 3. A single corresponding plug 8 is received therein. In this embodiment, play is (optionally) formed between the left-hand channel-separating web 12 according to the illustration and the (single) plug 8, with the result that, due to the component tolerance and/or the assembly tolerance, a leak may be present between the adjacent channel sections. The right-hand operating medium channel 4 according to the illustration is formed identically to that in FIG. 2, wherein here, the (single) plug 8 forms the outer wall 9 of the channel bend 10. Irrespective of the embodiment of the plug 8, said plug is (optionally) terminated here in a materially bonded and fluid-tight manner with respect to the receiving opening 7 by means of a laser weld seam 17.
(11) FIG. 4 shows a flow diagram of a production method for a heat exchange module 1 with optional steps d., e. and f. For understanding the production method, reference is made to the embodiments as per FIG. 1 to FIG. 3. In a step a., the module housing 3 and at least one plug 8 are provided, and then, in a step b., the plug 8 is inserted into the corresponding receiving opening 7, for example by means of pushing-in in the insertion direction 13. Beforehand, (optionally) in a step e. the channel bend 10 in the module housing 3 is prepared in that a channel-separating web 12 is shortened at the inner side of the channel bend 10 in the insertion direction 13 of the corresponding plug 8, for example by means of milling. Furthermore, in an (optional) step f., the receiving opening 7 is adapted to the requirements of the plug 8 and/or of the bonding method in step c., that is to say the shape is changed and/or the surface is machined. In an embodiment in which the receiving opening 7 is to be reworked as per step f., the receiving opening 7 is preferably reworked simultaneously, in a milling process, with the formation of the channel bend 10, wherein possibly (in the case of an end milling cutter with a diameter which is constant over its penetration length) the channel sections are extended in the region of a channel bend 10. The step c. comprises the fluid-tight bonding of the plug 8 to the receiving opening 7, for example by means of laser welding or friction stir welding. (Optionally finally), in an (optional) step d., the fluid connection 5 is formed in the plug 8, for example by means of drilling.
(12) FIG. 5 shows a motor vehicle 14 in a schematic plan view. In the region of the rear end, there is (optionally) arranged an (optionally electrical) drive machine 18 which, for the propulsion of the motor vehicle 14, is connected via a transmission 24 and a differential 25 to a rear left propulsion wheel 20 and to a rear right propulsion wheel 21. In the region of the front of the motor vehicle 14, there are arranged, preferably in a steerable manner, a front left propulsion wheel 22 and a front right propulsion wheel 23 which (optionally additionally or alternatively), also for propulsion, are connected in a torque-transmitting manner to a second (optionally electrical) drive machine 19. Here, provision is then made (optionally between the rear propulsion wheels 20,21 and the front propulsion wheels 22,23) of a heat exchange module 1, for example according to an embodiment in FIG. 1 to FIG. 3, which comprises an energy storage module 2, preferably in the form of a traction battery for providing a supply to at least one of the drive machines 18,19.
(13) With the heat exchange module proposed here, efficient use is made of a structural space, said heat exchange module at the same time being able to be manufactured at low cost.
