FR3152651A1 - Thermal regulation device, in particular for motor vehicles, and corresponding thermal regulation kit - Google Patents

Abstract

Corresponding thermal regulation assembly, in particular for a motor vehicle, and corresponding thermal regulation system The invention relates to a thermal regulation device (1) for the thermal regulation of at least one component (10) to be thermally regulated, this thermal regulation device (1) comprising: - at least two side walls (3) facing each other, - at least one bottom wall to which the two side walls (3) are connected so as to form a receiving housing (5) for at least one component (10) to be thermally regulated, the device (1) being characterized in that the two side walls are integral with the bottom wall, and - the device comprises a fluid circulation circuit (C) intended to be in contact with the component (10) to thermally regulate it, formed in at least one of the walls and at least one distribution orifice (6) and a recovery orifice (7) for the fluid configured to convey said fluid to and from the receiving housing. Figure for the abstract: Fig. 1

Description

Thermal regulation device, in particular for motor vehicles, and corresponding thermal regulation kit

The present invention relates to a thermal regulation device, in particular in the automotive field. Such a device generally defines a housing intended to receive modules of electrical and/or electronic components likely to release heat during their operation. The invention also relates to an electrical storage device comprising such a thermal regulation device in which the modules of electrical and/or electronic components are housed.

The components that may be covered by the present invention may be electrical energy storage elements, in particular battery elements, or power electronics, for example, but not limited to, semiconductors, such as diodes or transistors. They could also be computer server components.

The invention finds an alternative application in the field of thermal regulation of a power electronics device or module, i.e. comprising power electronic components. In operation, the temperature of such a power electronics device or module may rise, which risks damaging some of the power electronic components.

The invention also finds an advantageous application in the field of thermal regulation of electrical energy storage elements, such as battery cells, for example, for motor vehicles with electric and/or hybrid engines. The electrical energy of vehicles with electric and/or hybrid engines is supplied by one or more batteries. During their operation, the electrical energy storage elements such as the batteries are likely to heat up and thus risk being damaged. In particular, a charging technique, called fast charging, consists of charging the energy storage elements under a high voltage and a high amperage, in a short time, in particular in a maximum time of around twenty minutes. This fast charging involves significant heating of the electrical energy storage elements which must be treated.

In the field of motor vehicles, it is known to use a thermal regulation assembly, in particular for cooling, components for example for storing electrical energy, such as batteries. Such a thermal regulation assembly makes it possible to modify a temperature of an electrical energy storage device, for example when starting the vehicle in cold weather, by increasing its temperature for example, or whether during driving or during a recharging operation of said system, by reducing the temperature of the battery elements, which tend to heat up during their use.

According to a known solution, a dielectric fluid is sprayed and/or brought into contact with the components received in a housing, by means of a dielectric fluid circuit and orifices or nozzles for spraying the dielectric fluid. A heat exchange can then take place between the components and the dielectric fluid which comes into contact with a surface of the components. The dielectric fluid can be single-phase or two-phase. The latter is, for example, chosen according to its phase change temperatures.

Alternatively, components, such as electrical energy storage cells, are thermally regulated by immersion in a bath of dielectric fluid.

A constant problem concerns the integration of the dielectric fluid circuit by optimizing the quantity of dielectric fluid used while guaranteeing effective thermal regulation of all components.

The current battery system is dominated by cell-to-pack or module-to-pack technology. This requires the manufacturing of a pack with a large structural frame. Large production systems are required to produce these parts (large press, welding robot, assembly controls, screws, transport, etc.). The cell-to-frame strategy is new to the market and could be adopted quickly because it would require smaller production systems and potentially less energy, while offering greater modularity than the traditional cell-module-package strategy.

Current module designs rely on vertical assembly of the pack, many parts are required to integrate different functions such as cooling and HV circuit, so the pack is usually assembled sequentially (frame, bottom cover, cooler, cells/modules, HV circuit, top cover) and involves many manual operations (many screws).

The invention falls within this context and aims to offer an alternative to known thermal regulation devices, in particular in their application to an electrical storage device such as motor vehicle batteries, which makes it possible, among other things, to overcome the aforementioned problems.

To this end, the invention relates to a thermal regulation device for cooling and/or heating at least one electronic and/or electrical component to be thermally regulated, this component being in particular an electrical storage member, for example a battery cell, this thermal regulation device comprising:
- at least two side walls facing each other,
- at least one bottom wall to which the two side walls are connected so as to form a housing for receiving at least one component to be thermally regulated,
the device being characterized in that the two side walls are integral with the bottom wall, and
- the device comprises a fluid circulation circuit, in particular dielectric, intended to be in contact with the component to regulate it thermally, formed in at least one of the walls and at least one distribution orifice and one fluid recovery orifice configured to convey said fluid to and from the receiving housing.

In the context of immersion cooling, the invention makes it possible to have fewer different elements forming the receiving housing. This is thus proposed as a drawer with three or even four sides, receiving the electrical storage elements in a single-piece receiving structure, in particular extruded, the circuit and the fluid distribution and recovery orifices being integrated into this structure.

Advantageously, the invention proposes a simple structure that allows for packaging savings by avoiding the use of a large structural frame. Thus, crash safety aspects are transferred to the vehicle body, as is currently the case in internal combustion vehicles. This also allows for greater modularity because it is not dependent on the size of the battery pack; thanks to the invention, it is possible to easily increase or reduce the on-board electric range.

Advantageously, this also makes it possible to limit the number of fixings to be managed within the thermal regulation assembly while guaranteeing watertightness.

In fact, additional elements can then be added as desired to this base, particularly advantageously after inserting the components to be regulated such as electrical storage devices.

Thus, in some embodiments, the frame, walls, cover and cooling channels are all produced as a single piece which facilitates production and assembly.

This allows the number of parts and assembly operations to be minimized while ensuring spraying by the dielectric fluid or optimized immersion of the components when they are mounted in the thermal regulation device.

This allows the overall size of the device to be reduced by up to 10 times compared to a conventional battery pack, comprising modules and mounted under a vehicle chassis. The same applies to the production system, which is simplified and therefore reduced. The hollowed-out internal structure also allows the size of the device to be reduced by integrating cooling channels into the structure.

According to a feature of the invention, at least the side and bottom walls are overmolded with a thermoplastic composite. This overmolding can thus integrate specific functionalities, such as for example the insulation of the device.

The thermoplastic composite can, for example, be an organosheet composite, a thermoplastic matrix reinforced with glass fibers (woven or non-woven, disordered). The composite can thus be thermoformable and overmolded with compatible thermoplastic resins.

Preferably, the three walls have, in cross section, a U-shape with a bottom wall (X) to which the two opposite side walls (X), parallel to each other, are connected.

The thermal regulation assembly may further include one or more of the following features described below, taken separately or in combination.

At least two walls each comprise at least one fluid distribution conduit in which a dielectric fluid configured to thermally regulate the at least one component is intended to circulate,

The device further comprises a cover facing the bottom wall, and connected to the two side walls so as to form a parallelogram, preferably a rectangle.

The lid is made of the same material as the bottom wall and the side walls.

The device further comprises closure plates configured to be connected to the walls and the cover so as to hermetically close the receiving housing to the fluid.

The closure plates include supply and discharge ports connected to the fluid circulation circuit.

At least one closure plate comprises an electrical connection configured to be connected to the components to be regulated, for example to the busbars of storage devices such as battery cells.

The device comprises at least one seal arranged between at least one wall and/or cover of the regulating device and each closing plate.

The walls and/or the cover include supply and discharge ports connected to the fluid circulation circuit.

At least the walls, including the walls and the cover, are formed by extrusion, including pultrusion.

At least one side wall and/or cover comprises at least one fluid spray nozzle arranged in fluid communication with at least one dispensing orifice.

Each conduit having a predefined number of distribution orifices (6) of the dielectric fluid.

The cover includes fixing lugs to another cover of another regulating device.

The mounting legs can be offset from each other.

Advantageously, this allows aligned devices to be fixed, each comprising an identical cover. This thus makes it possible to produce only one cover shape.

The device does not include a spacer connecting two side walls or two closing walls.

The device comprises a spacer disposed in the receiving housing between at least two components.

The device further comprises at least one flexible member configured to compress said components when they are received in the receiving housing.

The invention also relates to an electrical storage device, comprising a thermal regulation device as claimed previously, and components to be regulated, in particular electrical energy storage members, the components being arranged in the form of at least one row of components, each row forming a module to be thermally regulated.

The invention also relates to a kit for forming a thermal regulation device as described above, comprising:
- a receiving housing formed by at least two side walls made of one material with a bottom wall, and a cover made of one material or not,
- two closing plates configured to hermetically seal the receiving housing against fluid.

• Extrusion, notamment par pultrusion, d’au moins les deux parois latérales et d’une paroi de fond, formant le dispositif et comprenant le circuit de circulation de fluide,
• Perçage des orifices de distribution et de récupération
• Mise en place des cellules au sein du dispositif,
• Optionnellement fixation d’un couvercle couplé aux parois latérales (3) et en regard de la paroi de fond, dans le cas où ledit couvercle n’est pas extrudé, notamment par pultrusion,
• Fermeture du dispositif par fixation de plaques de fermeture (9) afin de former un logement de réception fermé.

The invention also relates to a method for manufacturing an electrical storage device as described above, comprising the following steps:

• Extrusion, in particular by pultrusion, of at least the two side walls and a bottom wall, forming the device and comprising the fluid circulation circuit,
• Drilling the distribution and recovery holes
• Setting up cells within the device,
• Optionally fixing a cover coupled to the side walls (3) and facing the bottom wall, in the case where said cover is not extruded, in particular by pultrusion,
• Closing the device by fixing closing plates (9) in order to form a closed receiving housing.

The invention may also relate to a battery pack forming a storage device as defined above. The battery pack may comprise a predefined number of modules of several cells connected together.

Other advantages and characteristics of the invention will appear more clearly on reading the following description given as an illustrative and non-limiting example, and the appended drawings among which:

FIG. 1 is an exploded view of the electrical storage device comprising a thermal regulation device according to a first embodiment.

FIG. 2 is an exploded view of the electrical storage device comprising a thermal regulation device according to a second embodiment.

FIG. 3 is a partial sectional view of a thermal regulation device according to one embodiment.

In these figures, identical elements have the same reference numbers.

The following embodiments are examples. Although the description refers to one or more embodiments, this does not necessarily mean that each reference relates to the same embodiment, or that the features apply only to a single embodiment. Single features of different embodiments may also be combined or interchanged to provide other embodiments, without departing from the scope of the invention, as defined by the claims.

In the description, certain elements may be indexed, for example first element or second element. In this case, it is a simple indexing to differentiate and name close but not identical elements. This indexing does not imply a priority of one element over another and such names can easily be interchanged without departing from the scope of the present invention. This indexing also does not imply an order in time.

100 electrical storage device

Figures 1 to 2 show an example of an electrical storage device 100 which may be intended to equip a vehicle, in particular a motor vehicle. By way of non-limiting example, the electrical storage device 100 may be a battery pack.

The thermal regulation device 1 can define a general parallelepiped shape.

There FIG. 1 thus presents an electrical storage device 100 comprising a thermal regulation device 1 in which at least one module 13 is received.

Modules

The modules 13, when arranged within the thermal regulation system 1, may for example extend longitudinally in the length direction of the thermal regulation device 1.

Several rows of modules 13 may be intended to be received in the thermal regulation device 1. These rows of modules 13 are advantageously arranged parallel to each other. The rows of modules 13 may be aligned along the longitudinal axis of extension of the side and bottom walls (perpendicular to section A-A of figures 1 and 2).

Each module 13 may comprise a plurality of electronic and/or electrical components 10, such as energy storage cells, the temperature of which must be regulated, for example reduced. A module 13 corresponds, for example, to a group of cells connected to each other.

Alternatively, each module 13 comprising a plurality of electronic and/or electrical components 10 may correspond to an energy storage cell.

In the illustrated examples, the components 10 are represented schematically with a general parallelepiped shape. Of course, any other shape can be envisaged.

The components 10 can be arranged in rows within a module 13.

The temperature of the components 10 may be intended to be thermally regulated by immersing the components 10 of each module 13 in a bath of dielectric fluid. Alternatively, the thermal regulation may be carried out by spraying dielectric fluid onto one or more surfaces of the components 10. The dielectric fluid may be single-phase or two-phase. The latter is, for example, chosen according to its phase change temperatures.

In addition, at least one spacer can be arranged between two consecutive components 10 of a module 13. This makes it possible, in particular for a configuration of thermal regulation by immersion of the components 10, to guarantee that the dielectric fluid flows well between all the components 10.

In an alternative embodiment, as shown in Figures 1 and 2 by way of non-limiting example, the does not include a spacer connecting two side walls or two closing walls (9).

Thermal regulation device 1

The thermal regulation device 1 defines a receiving housing 5. This receiving housing 5 is intended to receive the modules 13.

This thermal regulation device 1 makes it possible to use a dielectric fluid to thermally regulate the modules 13.

Pultrusion is a continuous machining process for composite materials based on glass or carbon fiber. It consists of the extrusion of profiles with a constant and complex section by continuous traction, with polymerization in a closed mold.

The fluid circulation circuit C may comprise at least one fluid distribution conduit 2, for example between a supply orifice (11, 91) and an evacuation orifice (12, 92). The dielectric fluid is intended to circulate in the fluid distribution conduit(s) 2.

The conduit(s) 2 may be made in the form of continuous hollow spaces, for example formed by machining, extrusion, molding, preferably by extrusion. The ends of the conduits, in particular in the case where they are formed by extrusion, are closed, for example by the closing plates 9.

In some embodiments, as shown by way of example in FIG. 3 , for example formed by extrusion, hollow spaces 16 are likely to be formed within the side walls 3, bottom 4 and cover 8. These hollow spaces 16, empty and closed at their end, advantageously make it possible to reduce the weight of the device without losing reliability and rigidity of the walls.

In some embodiments, as shown by way of example in FIG. 1 and 2, the thermal regulation device 1 further comprises at least two closing walls 9, i.e. one closing wall 9 for each longitudinal end of the receiving housing formed by the side walls 3 and the bottom wall 4.

The closing walls 9 may optionally be made at least partly from a composite plastic material, advantageously heat-resistant.

The closing walls 9 are fixed to at least one of the side walls 3 and the bottom wall 4. The fixing can be done by screwing. Any other means of fixing can be considered. This advantageously makes it possible to require fewer parts, fewer fixing elements, such as screws, and thus less assembly time.

In some embodiments, at least one seal is provided between the closing wall 9 and the element to which it is fixed. When the assembly is carried out by screwing, by tightening the screws, the seals can be compressed, for example in the same operation.

The closing wall 9 may have a rim or a peripheral flange coming into contact with the wall or cover to which it is fixed. Housings may be provided in this peripheral flange for the passage of fixing elements, such as screws for example when the fixing is done by screwing, or for the electrical connection 93 of the closing plates 9 with the busbars 14 of the components 10 such as storage members.

Each closing wall 9 may have a foot or edge.

As shown in the FIG. 2 , each closing wall 9 may comprise, in particular on this foot or edge, a connection or tapping 91, 92 connected to a fluid distribution conduit 2 for the arrival or drainage of the dielectric fluid. For example, the closing wall 9 may comprise a supply orifice 91 connected to the fluid distribution conduit 2 and an evacuation orifice 92 on the fluid distribution conduit 2.

The supply orifice 91 may be at a foot or edge of the closing wall 9 and the discharge orifice 92 may be at the opposite foot or edge of this same closing plate 9.

The seal may be maintained between a foot or edge of a closing wall 9 and the wall to which said closing wall is fixed. The seal is preferably also arranged between the entire peripheral periphery of the closing wall and the wall to which said closing wall is fixed.

The two closing plates are for example each arranged in contact with or directly above connectors, an interconnection bar or a set of bars 14 (busbar in English) allowing the components 2 to be connected to each other. For example, a space can be provided above the connectors to house the interconnection bars, which are elements subject to high thermal stress during operation.

In some embodiments, the fluid volume and/or the orifices are sized so that the connectors and/or interconnection bar or a busbar 14 are thermally regulated by contact with the dielectric fluid.

In certain embodiments, the circulation circuit C has a predefined number of distribution orifices 11 and evacuation orifices 12 for the dielectric fluid. These orifices 11, 12 allow the flow or projection, and the evacuation of the dielectric fluid to immerse or spray the components 2.

According to another variant embodiment (not shown), the device 1 may comprise at least one dielectric fluid spray nozzle arranged in fluid communication with at least one fluid distribution orifice 11, 91. Such a nozzle is also called a nozzle.

The nozzle(s) may each comprise one or more orifices for projecting the dielectric fluid. They may be arranged so as to project and spray dielectric fluid onto at least one surface of at least one component 2.

When there is a multiplicity of nozzles, they may be identical or different, have the same number of projection orifices or not, have projection orifices of the same opening area or not, for example of the same diameter or not. The nozzles may be arranged in an identical or substantially identical orientation, or in variable orientations, relative to the components 7 of each module 5.

Furthermore, for each receiving housing, at least one flexible member can be provided. This flexible member can be made, for example, in the form of a spring wedge.

The flexible member is for example arranged inside the volume defined between a closing wall 9 and a component 2. It can in particular be arranged to bear against an internal surface of the closing wall 9.

When the components 2 are received within the thermal regulation device 1, the flexible members allow the components 2 to be compressed. The components 2 are thus kept tightly against each other. The flexible members allow the differences in size of the components 2 to be absorbed, particularly during operation or under load, for example. Alternatively, foam elements could be considered.

The thermal regulation device 1 may also comprise one or more elements or organs necessary for the circulation of the dielectric fluid and the thermal regulation of the components 2.

Legend
1. Thermal regulation device
2. Fluid distribution conduit
3. Side walls
4. Back wall
5. Reception accommodation
6. Distribution orifice
7. Recovery port
8. Cover
9. Closing plate
10. Electronic and/or electrical components
11. Feed holes on a wall/cover
12. Drain holes on a wall/cover
13. Module
14. Busbar
15. Fixing lug
16. Hollow space
91. Feed port on a closure plate
92. Drain hole on a closing plate
93. Electrical connection
100. Electrical storage device
C. dielectric fluid circulation circuit

Claims (10)

Thermal regulation device (1) for cooling and/or heating at least one electronic and/or electrical component (10) to be thermally regulated, this component (10) being in particular an electrical storage member, for example a battery cell, this thermal regulation device (1) comprising:
- at least two side walls (3) facing each other,
- at least one bottom wall to which the two side walls (3) are connected so as to form a receiving housing (5) for at least one component (10) to be thermally regulated,
the device (1) being characterized in that the two side walls are integral with the bottom wall, and
- the device comprises a fluid circulation circuit (C), in particular dielectric, intended to be in contact with the component (10) to regulate it thermally, formed in at least one of the walls and at least one distribution orifice (6) and one recovery orifice (7) of the fluid configured to convey said fluid to and from the receiving housing. Thermal regulation device (1) according to the preceding claim, wherein the device (1) further comprises a cover (8) facing the bottom wall (4), and connected to the two side walls (3) so as to form a parallelogram, preferably a rectangle. Thermal regulation device (1) according to the preceding claim, in which the cover is made in one piece with the bottom wall 4 and the side walls 3. Thermal regulation device (1) according to one of claims 2 or 3, wherein it further comprises closing plates (9) configured to be connected to the walls and to the cover so as to hermetically close the receiving housing (5) to the fluid. Control device (1) according to one of claims 1 to 4, in which at least the walls (3, 4), in particular the walls (3, 4) and the cover (8), are formed by extrusion, in particular by pultrusion. Regulating device (1) according to one of claims 1 to 5, in which at least one side wall (3) and/or cover (4) comprises at least one fluid spray nozzle arranged in fluid communication with at least one dispensing orifice (6). Regulation device (1) according to one of claims 2 to 6, in which the cover comprises fixing lugs (15) to another cover (8) of another regulation device (1). Electrical storage device (100), comprising a thermal regulation device according to one of the preceding claims, and components to be regulated (10), in particular electrical energy storage members, the components (10) being arranged in the form of at least one row of components (10), each row forming a module (13) to be thermally regulated. Kit for forming a thermal regulation device (1) according to one of claims 1 to 7, comprising:
- a receiving housing (5) formed by at least two side walls made of one material with a bottom wall, and a cover made of one material or not,
- two closing plates (9) configured to hermetically close the receiving housing (5) to the fluid. A method for manufacturing an electrical storage device (100) according to claim 8, comprising the following steps:

• Extrusion, in particular by pultrusion, of at least the two side walls (3) and a bottom wall, forming the device and comprising the fluid circulation circuit (C),
• Drilling the distribution (6) and recovery (7) orifices
• Setting up cells within the device (1),
• Optionally fixing a cover coupled to the side walls (3) and facing the bottom wall, in the case where said cover is not extruded, in particular by pultrusion,
• Closing the device by fixing closing plates (9) in order to form a closed receiving housing.