Modular heat exchange system applied to a battery module and its manufacturing process.

Description

1 / 12 Descriptive Report of Invention Patent Modular Thermal Exchange System Applied to Battery Module and its Manufacturing Process Field of Invention

[0001] This report covers confidential knowledge, information and / or data usable in industry, commerce or service provision, for which the holder requires: the protection established in item XXIX of Article 5 of the Federal Constitution; the maintenance of the legal status of confidentiality / secrecy; the maintenance of the physical status of confidentiality / secrecy for the time stipulated in Law 9.279 / 96, Industrial Property Law; and the rights provided for in Article 195 of Law 9.279 / 96. The present invention describes a modular heat exchange system applied to a battery module, a manufacturing process thereof, a vehicle comprising at least one battery module and a heat exchange system and battery module kit, more specifically in the fields of electrical engineering and mechanical engineering, focused on the area of ​​cooling systems for automotive batteries and electrical power systems. Background of the Invention

[0002] Battery cooling systems are widely used in electric vehicles (EVs) and hybrid vehicles (HEVs) to maintain battery temperatures within an ideal range. Furthermore, battery thermal management is fundamental to ensuring battery performance, longevity, and safety, so cooling systems play a crucial role in the operation of the entire system.

[0003] In current cooling systems, air is commonly used as a cooling fluid, where air circulation is used to dissipate the heat generated by the batteries during charging and discharging.

[0004] However, these air cooling systems have low efficiency, Petition 870240111493, dated 12 / 31 / 2024, page 6 / 56 2 / 12 because the heat dissipation capacity of air-cooled systems is limited. Under high energy demand conditions, it can be difficult to maintain the battery within the ideal temperature range, especially in hot and cold climates when there is a need to heat the battery to the optimal operating point. Similarly, precise temperature control is difficult, and the system's effectiveness can vary significantly depending on environmental conditions such as air temperature and humidity.

[0005] Furthermore, many current cooling systems have elements and components that make assembly with the battery pack difficult, as well as lacking configurable geometry that allows for customizing the configuration and quantity of cooling systems according to the number of batteries in the pack.

[0006] Furthermore, current battery cooling systems are manufactured from heavy metal alloys, which considerably increase the overall weight of the vehicle.

[0007] In the search for the state of the art in scientific and patent literature, no documents were found that deal with the subject. Thus, as can be inferred from the literature researched, no documents were found anticipating or suggesting the teachings of the present invention, so that the solution proposed here has novelty and inventive activity compared to the state of the art. Summary of the Invention

[0008] Thus, the present invention solves the problems of the prior art by means of a modular heat exchange system applied to the battery module base, designed to allow its configuration to be adjusted according to the battery size, allowing different sets of battery modules to be cooled and / or heated by the present system.

[0009] In this sense, an object of the invention is a heat exchange system that Petition 870240111493, dated 12 / 31 / 2024, page 7 / 56 3 / 12 provides optimized cooling and / or heating of the battery module, since the heat exchange system itself is used to cool and / or heat the battery modules. Furthermore, heat exchange between the fluid and the components is maximized through internal channels in the components equipped with fins, providing greater cooling efficiency.

[0010] Another object of the invention is a heat exchange system manufactured by an extrusion process, providing gains in the manufacturing time of parts, reduction of machining steps of parts, as well as reduction of welding steps of parts.

[0011] In a first object, the present invention provides a modular heat exchange system applied to a battery module comprising at least one central plate and at least two left and right side plates fixed to the central plate, wherein the left side plate comprises a geometry symmetrical or asymmetrical to the right side plate.

[0012] In a second object, the present invention discloses a manufacturing process for a modular heat exchange system applied to a battery module comprising the steps of: a. manufacturing of at least one central plate in extruded aluminum; b. manufacturing of a left and right side plate in extruded aluminum, the left side plate comprising a geometry symmetrical or asymmetrical to the right side plate; and c. fixing the left and right side plates to the center plate by means of friction welding.

[0013] In a third object, the present invention provides a vehicle comprising at least one battery module, wherein the battery module is associated with a modular heat exchange system applied to the base of the battery module, wherein the modular cooling system comprises at least one central plate and at least two left and right side plates fixed to the central plate, wherein the left side plate comprises symmetrical geometry. Petition 870240111493, dated 12 / 31 / 2024, page 8 / 56 4 / 12 or asymmetrical to the right side plate.

[0014] In a fourth object, the present invention provides a modular heat exchange system kit and battery module comprising a set of plates associated with the base of the battery module (10), wherein the set of plates comprises at least one central plate and at least two left and right side plates fixed to the central plate, wherein the left side plate comprises geometry symmetrical or asymmetrical to the right side plate.

[0015] These and other objects of the invention will be immediately appreciated by those skilled in the art and will be described in detail below. Brief Description of the Figures

[0016] The following figures are presented:

[0017] Figure 1 shows an embodiment of the heat exchange system of the present invention, illustrating the central plate (1) and the left (2) and right (3) side plates.

[0018] Figure 2 shows an embodiment of the heat exchange system of the present invention, illustrating the channels (9) of the plates.

[0019] Figure 3 shows an embodiment of the heat exchange system of the present invention, illustrating the fluid-filled plate channels (9).

[0020] Figure 4 shows a cross-sectional view of the plates (1, 2, 3), illustrating the fins present in the channels (9).

[0021] Figure 5 shows a front view of the channels (9), illustrating the fins positioned on the upper and lower inner walls of the channel (9).

[0022] Figure 6 shows an embodiment of the closing plate (8) and the highlighted inlet and outlet nozzle (11), which are fixed to the side plates (2, 3).

[0023] Figure 7 shows one of the possible length configurations of the heat exchange system and the arrangement of the battery modules (10), highlighting the modular concept.

[0024] Figure 8 shows one of the possible configurations of the length of Petition 870240111493, dated 12 / 31 / 2024, page 9 / 56 5 / 12 heat exchange system and battery module arrangement (10), highlighting the modular concept.

[0025] Figure 9 shows one of the possible configurations of the length of the heat exchange system and the arrangement of the battery modules (10), highlighting the modular concept.

[0026] Figure 10 shows one of the possible configurations of the length of the heat exchange system and the arrangement of the battery modules (10), highlighting the modular concept.

[0027] Figure 11 shows a realization of the association profile of the left (2) and right (3) side plates.

[0028] Figure 12 shows a front view of the boards, illustrating the channels (9) and different possible configurations.

[0029] Figure 13 shows different configurations of the heat exchange system sizes and the arrangement of the battery modules (10).

[0030] Figure 14 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0031] Figure 15 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0032] Figure 16 shows a perspective view of the left side plate (2).

[0033] Figure 17 shows a front view of the left side plate (2).

[0034] Figure 18 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0035] Figure 19 shows a close-up view of an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0036] Figure 20 shows a close-up view of an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0037] Figure 21 shows a realization of the heat exchange system, Petition 870240111493, dated 12 / 31 / 2024, page 10 / 56 6 / 12 illustrating the connection of the side plates (2, 3) to the central plate (1).

[0038] Figure 22 shows a close-up view of the channels (9) of the plates (1,2, 3).

[0039] Figure 23 shows a perspective view of the heat exchange system of the present invention, illustrating a configuration of three associated plates, being a central plate (1) and two side plates (2, 3). Detailed Description of the Invention

[0040] The present invention describes a modular heat exchange system applied to the battery base comprising a set of plates configured according to the battery size, the plates comprising internal channels fitted with fins that maximize heat exchange between the fluid and the plates.

[0041] Furthermore, the plates are manufactured through an extrusion process, which optimizes manufacturing time and reduces machining and welding steps on the parts.

[0042] In a first object, the present invention provides a modular heat exchange system applied to the base of a battery module, comprising at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), wherein the left side plate (2) comprises geometry symmetrical or asymmetrical to the right side plate (3).

[0043] Furthermore, the system of the present invention comprises modular geometry that allows configuring the plates in relation to the size of the battery modules, that is, this concept allows the joining of plates side by side to form a system that accommodates different sizes of battery modules (10) / capacities.

[0044] In one embodiment, the central plate (1) has a defined width based on the size of the battery module to which it is associated.

[0045] In this way, the heat exchange system is formed by a set of plates that are positioned at the base of the battery module and have the objective Petition 870240111493, dated 12 / 31 / 2024, page 11 / 56 7 / 12 to cool and / or heat the battery. To this end, in one embodiment, the central plate (1) and the left (2) and right (3) side plates comprise channels (9) for circulation of the heat exchange fluid, the channels comprising finned profile geometry on the upper and lower inner walls which increase the efficiency of heat exchange by maximizing the contact area of ​​the fins with the fluid.

[0046] In one embodiment, each of the left (2) and right (3) side plates comprises two side faces, one face being for attachment to the center plate (1), and one face having at least one mounting profile comprising at least one mounting hole to the vehicle (5), at least one mounting hole in the battery module (6) and at least one mounting hole for the battery cover (7).

[0047] In one embodiment, the connection profile comprises symmetrical or asymmetrical geometry on the left (2) and right (3) side plates, being used to connect the system to the vehicle by means of the vehicle connection hole (5), to connect the system to the battery module (10) by means of the connection hole in the battery module (6), and to connect the battery module (10) to the cover by means of a battery cover connection hole (7).

[0048] In one embodiment, the system comprises a closing plate (8) which is fixed to the central plate (1) and to the left (2) and right (3) side plates. In one embodiment, the closing plate (8) is welded to the plates (1, 2, 3).

[0049] In one embodiment, the closing plates (8) fixed to the left side plate (2) and to the right side plate (3) comprise an inlet and outlet nozzle (11) for inserting or discharging heat exchange fluid into the channels (9) of the plates.

[0050] In this way, after the fluid circulates through all the channels of the system, the fluid is conducted out of the plate assembly, passing through the inlet and outlet nozzle (11) and returning to a battery heat exchange management system, which is positioned externally to the exchange system. Petition 870240111493, dated 12 / 31 / 2024, page 12 / 56 8 / 12 thermal version of the present invention.

[0051] In a second object, the present invention discloses a manufacturing process for a modular heat exchange system applied to a battery module comprising the steps of: a. manufacture of at least one central plate (1) in extruded aluminum; b. manufacture of a left (2) and right (3) side plate in extruded aluminum, the left side plate (2) comprising a geometry symmetrical or asymmetrical to the right side plate (3); and c. fixing the left (2) and right (3) side plates to the center plate (1) by means of friction welding.

[0052] The manufacture of plates (1, 2, 3) through an aluminum extrusion process provides several procedural and product advantages, such as reduced manufacturing time, since the extrusion process allows the generation of parts with a more precise finish, reducing the number of machining and welding steps of the parts.

[0053] Furthermore, manufacturing the parts (1, 2, 3) in aluminum provides lighter parts, reducing the total weight of the system as a whole and consequently reducing the weight of the vehicle's battery pack (10).

[0054] In one embodiment, the central plate (1) is fixed to the side plates (2, 3) by means of friction welding, allowing greater precision in fixing the parts and reducing deformations and failure regions in the welding.

[0055] In one embodiment, the central plate (1) and the left (2) and right (3) side plates are manufactured with internal channels (9) for the circulation of heat exchange fluid, wherein the channels comprise finned profile geometry on the upper and lower parts of the inner walls of the channel (9). In this way, the extrusion process allows the plates to be manufactured directly with the finned internal channels (9), resulting in process time savings and a reduction in machining and milling steps. Petition 870240111493, dated 12 / 31 / 2024, page 13 / 56 9 / 12

[0056] Furthermore, the manufacture of internal channels (9) with fins provides an energy efficiency gain in heat exchange between the fluid passing through the channel and the fins due to the increased contact area for heat exchange.

[0057] In one embodiment, the manufacturing process of the system also includes a modular assembly step of the left (2) and right (3) side plates onto the central plate (1), according to the battery configuration (10), this step being carried out prior to the welding step of the side plates (2, 3) to the central plate (1). In this step, the system configuration can be customized according to the size and types of battery cells, adding or removing associated central plates (1). Thus, the modularization concept allows the configuration of different types of battery packs, as needed.

[0058] In one embodiment, the process comprises a manufacturing step of at least one closing plate (8) and joining the closing plates (8) to the central plate (1) and to the left (2) and right (3) side plates. In one embodiment, the closing plates (8) joined to the side plates (2, 3) are manufactured comprising an inlet and outlet nozzle (11) disposed in the closing plate (8), to allow the entry and exit of the heat exchange fluid in the system.

[0059] In this way, the manufacturing process also includes a step of inserting heat exchange fluid into the left (2) and / or right (3) side plate by means of said inlet and outlet nozzle (11), so that the fluid flows through the channels (9) of the plates (1, 2, 3) and / or to check for any leaks and validate the product.

[0060] In a third object, the present invention provides a vehicle comprising at least one battery module (10), wherein the battery module (10) is associated with a modular heat exchange system applied to the base of the battery module (10), wherein the modular cooling system comprises at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), such that the side plate Petition 870240111493, dated 12 / 31 / 2024, page 14 / 56 10 / 12 left (2) comprises geometry that is symmetrical or asymmetrical to the right side plate (3).

[0061] In this way, the modular heat exchange system of the present invention allows optimizing the cooling and / or heating of vehicle batteries, providing the following advantages: lighter and more resistant system, since the plates (1, 2, 3) are manufactured from extruded aluminum and efficient, since it is manufactured from extruded aluminum; greater energy efficiency, since the plates (1, 2, 3) are equipped with channels (9) with fins that maximize heat exchange between the fluid and the plates; and modularization of the number of plates (1, 2, 3) associated according to the size / capacity of the vehicle batteries.

[0062] In a fourth object, the present invention provides a modular heat exchange system kit and battery module comprising a set of plates associated with the base of the battery module (10), wherein the set of plates comprises at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), wherein the left side plate (2) comprises geometry symmetrical or asymmetrical to the right side plate (3).

[0063] The examples shown here are intended only to illustrate one of the numerous ways of carrying out the invention, however without limiting its scope. Example 1 - Heat Exchange Base for Batteries

[0064] In this example, a battery base was developed with a heat exchange system for cooling and / or heating the battery modules associated with the base. In this sense, the concept developed allows the base itself to be used as a cooling / heating system for the battery modules (10).

[0065] The base is formed by at least 3 plates, being a central plate (1), and two left (2) and right (3) side plates, wherein the left side plate (2) has a geometry symmetrical or asymmetrical to the right side plate. Petition 870240111493, dated 12 / 31 / 2024, page 15 / 56 11 / 12 (3). The base is as illustrated in figures 1, 21, 23 and 24.

[0066] The two side plates (2, 3) are fixed one on each side face of the central plate (1) by means of friction welding. This concept allows the modularization of the base, using central plates with different sizes with more or fewer channels for fluid circulation (1) according to the size, type, configuration of the battery modules to be associated with the base. In this way, prior to welding the plates, the base can be customized through the modularization of the plates, according to the need. Figures 7, 8, 9, 10 and 13 show different configurations of base length and arrangement of modules (10) on top of the base.

[0067] Each plate (1, 2, 3) has internal channels (9) for the passage of the heat exchange fluid, as illustrated in figures 2 and 3, where figure 2 illustrates the empty channels (9) and figure 3 illustrates the channels (9) filled with fluid. The channels (9) have fins arranged on the upper and lower walls of the channels (9), so that these fins promote greater heat exchange between the fluid and the plates by maximizing the contact area of ​​the fluid with the fins of the plates (figure 12). Furthermore, figures 4, 5 and 6 highlight the channels (9) equipped with fins through which the heat exchange fluid passes. Moreover, the curves for the passage and direction of the fluid flow are formed by the geometric configuration of the channels (9) themselves.

[0068] In addition, the left (2) and right (3) side plates have an association profile located on the face opposite the face for fixing to the central plate (1). As illustrated in Figure 11, the association profile has a vehicle association hole (5) for fixing the base to the vehicle, a battery module association hole (6) for fixing the battery modules (10) to the base, and a battery cover association hole (7) for fixing the protective cover to the base. These fixings are made by means of screws that run through the profiles (5, 6, 7). Figures 14, 15, 18, 19 and 20 show the base associated with the battery modules (10).

[0069] For closing the channels (9), the developed base has plates of Petition 870240111493, dated 12 / 31 / 2024, page 16 / 56 12 / 12 closure (8) fixed to the plates (1, 2, 3) by welding. The closure plates (8) of the left (2) and right (3) side plates have an inlet and outlet nozzle (11) for inserting or discharging the heat exchange fluid into the channels (9) of the plates (2, 3). Figure 6 illustrates the closure plate (8) in detail.

[0070] Furthermore, the plates (1, 2, 3) and the closing plates (8) are manufactured by means of an aluminum extrusion process, which allows the manufacture of the internal channels (9) of the plates (1, 2, 3), reducing the need for machining and milling steps. This provides a time saving in the plate manufacturing process, as well as a reduction in welding steps in the manufacturing. Moreover, manufacturing in aluminum provides a reduction in the weight of the plates, when compared with plates made of other metal alloys in the prior art.

[0071] Figure 16 shows a perspective view of the left side plate (2), illustrating the association profile and channels (9).

[0072] Figure 17 shows a front view of the left side plate (2).

[0073] Figure 22 shows a view highlighting channel (9) of the plate.

[0074] The inventive concept now disclosed and exemplified in one or more ways has been treated as a trade secret and was not previously disclosed until the filing of this patent application. This trade secret is an intangible asset of the applicant. Any future publication of the patent application does not, in itself, constitute authorization for use by third parties, serving only as: (i) notification to third parties of the existence of said trade secret on the filing date; (ii) unequivocal indication of its holder; and (iii) encouragement to develop new improvements based on the concept now disclosed, to avoid reinvestment in the development of the same asset already held by the applicant.In this context, it is clarified from the outset that, based on the disclosure of the present inventive concept, those skilled in the art may consider other ways of carrying out the invention that are not identical to those merely exemplified above, but that, in the event of an intention to use it commercially, such ways may be considered as being within the scope of the appended claims. Petition 870240111493, dated 12 / 31 / 2024, page 17 / 56

Claims

1 / 3 Claims 1. Modular heat exchange system applied in a battery module characterized by comprising at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), wherein the left side plate (2) comprises geometry symmetrical or asymmetrical to the right side plate (3).

2. System according to claim 1, characterized in that the central plate (1) and the left (2) and right (3) side plates comprise heat exchange fluid circulation channels (9) comprising finned profile geometry on the upper and lower inner parts.

3. System according to claim 1, characterized in that each of the left (2) and right (3) side plates comprises two side faces, one face for fixing to the central plate (1), and one face provided with at least one connection profile comprising at least one connection hole to the vehicle (5), at least one connection hole in the modules (6) and at least one connection hole for the battery cover (7).

4. System, according to claim 1, characterized in that the central plate (1) has a width defined as a function of the size of the battery module to which it is associated.

5. System according to claim 1, characterized by comprising at least one closing plate (8) fixed to the central plate (1) and to the left (2) and right (3) side plates.

6. System according to claim 1, characterized by the modular mounting concept of the central plate (1) and the left (2) and right (3) side plates adapting to different battery cell configurations.

7. Manufacturing process of a modular heat exchange system applied to a battery characterized by comprising the steps of: a. manufacturing at least one central plate (1) in extruded aluminum; Petition 870240111493, dated 12 / 31 / 2024, page 18 / 56 2 / 3 b. manufacturing a left (2) and right (3) side plate in extruded aluminum, the left side plate (2) comprising a geometry symmetrical or asymmetrical to the right side plate (3); and c. fixing the left (2) and right (3) side plates to the central plate (1) by means of friction welding.

8. Manufacturing process of a system, according to claim 7, characterized in that the central plate (1) and the left (2) and right (3) side plates are manufactured with internal channels (9) for circulation of heat exchange fluid comprising finned profile geometry in the upper and lower parts.

9. Manufacturing process of a system, according to claim 7, characterized by comprising a modularized assembly step of the left (2) and right (3) side plates onto the central plate (1), according to the configuration of the battery module (10), prior to the soldering step.

10. A manufacturing process for a system according to claim 7, characterized by comprising a manufacturing step of at least one closing plate (8) and joining the closing plates (8) to the central plate (1) and to the left (2) and right (3) side plates.

11. A manufacturing process for a system according to any one of claims 7 to 10, characterized by comprising a step for inserting heat exchange fluid into the left (2) and / or right (3) side plate by means of an inlet and outlet nozzle (11) disposed in the closing plate (8).

12. Vehicle comprising at least one battery module characterized in that the battery module (10) is associated with a modular heat exchange system applied to the base of the battery module (10), wherein the modular cooling system comprises at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), wherein the left side plate (2) comprises geometry symmetrical or asymmetrical to the right side plate (3). Petition 870240111493, dated 12 / 31 / 2024, page 19 / 56 3 / 3 13. Modular heat exchange system kit and battery module characterized by comprising a set of plates associated with the base of the battery module (10), wherein the set of plates comprises at least one central plate (1) and at least two left (2) and right (3) side plates fixed to the central plate (1), wherein the left side plate (2) comprises a geometry symmetrical or asymmetrical to the right side plate (3). Petition 870240111493, dated 12 / 31 / 2024, page 20 / 56

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