One-piece filter element for fluid recirculation system of air conditioning system, such as system for cooling battery assembly, in particular for electric vehicle

Abstract

A filter element (1) suitable for use in a fluid recirculation system of an air conditioning system for cooling or heating one or more components, such as, for example, a battery pack, in particular for a vehicle, comprising a hollow filter portion (4) and a hollow constrained end portion (3). The filter portion (4) is manufactured as a single piece with the constraining portion (3) and, in use, is inserted directly into a first conduit (60) of a cooling system, the first conduit (60) and a second conduit (50) of the system being directly connected to said hollow constraining end portion (3).

Description

[0001] The object of the present invention is a filter element adapted to be used in a fluid recirculation system for air conditioning, i.e. during its operation or use, heating or cooling one or more components subjected to temperature variations, such as a battery or accumulator according to the preamble of the main claim. This preamble is reported in US2003 / 201222.

[0002] In particular, the present invention relates to a system for cooling a battery assembly or battery pack used for driving part or all of an electric vehicle in the automotive industry. In this document, for simplicity, reference will be made to the use of the present invention for cooling a battery assembly in a motor vehicle; this use is provided only by way of non-limiting example.

[0003] In this document, the expression "battery assembly" is used to denote both a group of lithium batteries or another type of battery, as well as a fuel cell. Considering that both types of batteries need to be cooled, they are usually associated with a system that appropriately cools them with a suitable and known refrigerant.

[0004] In the cooling system, there is at least one filter element that particularly filters particulate impurities present in the circulating fluid after the system has been filled with particulate impurities.

[0005] Various types of filter elements are known to be suitable for performing the above functions: among them, it is important to avoid the deposition of the above impurities on the filter surface of the element to avoid a reduction in the cross-sectional area of the cooling fluid passage in the system, and this can lead to dangerous consequences in the battery.

[0006] Generally, known filter elements include a body having a filtering portion and a rigid portion connected to this portion; this body is usually inserted and held enclosed in a housing, and the ends of the housing (or at least one of them) are connected to the conduits of the cooling system. This end of the housing is shaped to be connected to the conduit, or they are provided with fittings adapted to facilitate the constraint of the housing to the above conduit. Alternatively, only one end of the housing is connected to the conduit of the cooling system. The other conduit of the cooling system is directly connected to the rigid portion of the body of the filter element.

[0007] In order to form a cross-section that helps the flow of the cooling fluid through the filter element in the housing, the filtering portion of the element is preferably conical, or however tapers towards the empty end along its longitudinal axis.

[0008] Therefore, this type of filter element provided with a housing requires the production of multiple components that must be assembled together before being inserted into the cooling system, and the use of possible sealing elements in the area where the filter element and the associated housing are coupled to the cooling system.

[0009] Furthermore, as happens for the filter element described, for example, in US2020 / 0054973, the tapered end portion of the filtering section (concave in this prior art document) becomes a location where impurities accumulate, and this is harmful to the correct flow of the cooling fluid and the filtration pattern.

[0010] An object of the present invention is to provide a filter element for a fluid recirculation system for air-conditioning one or more components during its operation or use, cooling or heating them.

[0011] In particular, an object of the present invention is to provide a filter element for a system for cooling, in particular, a battery assembly for an electric vehicle, the filter element being an improvement over the prior art filter elements used in the prior art cooling systems for battery assemblies used in vehicles.

[0012] Another object of the present invention is to provide a filter element of the above type that can be quickly and easily coupled to an air-conditioning fluid recirculation system and that, at the same time, ensures a sealed and normal flow of the cooling fluid in the system and through the filter element.

[0013] Another object is to provide a filter element of the above type in which the filtering surface is maximized with respect to the dimensions of the element while reducing any pressure drop in the cooling system.

[0014] Another object is to provide a filter element in which the stagnation of the cooling fluid is minimized while optimizing the filtration performance and the flow in the circuit.

[0015] These and other objects, which will be more apparent to those skilled in the art, are achieved by a filter element according to the appended independent claims and dependent claims.

[0016] For a better understanding of the present invention, the following drawings are attached by way of non-limiting example only, in which:

[0017] Figure 1 A perspective view of a filter element according to the present invention is shown from one side;

[0018] Figure 2 is shown Figure 1 a side view of the filter element;

[0019] Figure 3 is shown according to Figure 1 a cross-sectional view taken along line 3-3;

[0020] Figure 4 is shown Figure 1 a perspective view of a first variant of the filter element;

[0021] Figure 5 A view of the filter element shown from the left; Figure 4 of;

[0022] Figure 6 Shows Figure 1 a perspective view of a second variant of the filter element of; and

[0023] Figure 7 Shows a cross-sectional view taken along line 7-7 according to Figure 6 of;

[0024] Figure 8 Shows Figure 1 a perspective view of a third variant of the filter element of;

[0025] Figure 9 Shows Figure 8 a front perspective view of a variant of;

[0026] Figure 10 Shows a cross-sectional view taken along line 10-10 according to Figure 8 of; and

[0027] Figure 11 Shows in plan view a section of Figure 10 of.

[0028] First, referring to Figures 1 to 3 , the filter element is generally designated by 1. It includes a hollow tubular body 2 having a first part 3, and a second part 4 projects from the first part 3. The first part 3, which will hereinafter be referred to as the restraint part 3, includes a hollow tubular body 5 which may also be rigid, peripherally closed and having a radial jacket ring 6 which divides the tubular body into two cylindrical connecting parts 5A, 5B, each having a terminal tapered end 8 projecting from the corresponding cylindrical part. Thus, a step 11 is created between the base of each tapered end 8 and the corresponding cylindrical connecting parts 5A, 5B.

[0029] On the hollow tubular (rigid) body 5 there are projections 14 which are provided with through-holes 15 and are arranged in diametrically opposite positions relative to each other. The projections 14 are for fixing the filter element 1 to a suitable support, for example to conduits 50 and 60 of a battery cooling system (not shown) Figure 2 ), the battery cooling system being used in the field of motor vehicles having an electric motor, a battery which may for example have lithium, be in solid state, or may be defined by a fuel cell for a hydrogen-powered vehicle. This use of the system for cooling the battery in the automotive industry is provided only by way of non-limiting example, and the filter element is also suitable for use in other air conditioning systems (for heating or cooling).

[0030] A second part 4, hereinafter referred to as the filtering part 4, is hollow tubular; it includes a hollow tubular body 16, which can be rigid and is preferably cylindrical, provided with a longitudinal opening 17 (which is longitudinally distributed on the hollow tubular body 16) and obtained around a filtering member 18. The tubular body 16 extends substantially from a part 5B of the above-mentioned first part 3, and it includes circumferential ribs 19 (which are located in a plane P orthogonal to the longitudinal axis W of the filtering part 4, and this longitudinal axis W coincides with the longitudinal axis of the entire filtering element 1), and the circumferential ribs 19 are connected to longitudinal ribs 20 (parallel to the above-mentioned axis W) protruding from the circumferential ribs 19. The longitudinal ribs 20 are manufactured as a single piece with the part 5B and thus with the part 3. In any case, along the entire filtering part 4 (i.e., along its axis W), a cross-section with a constant diameter K ( Figure 2 ) is defined, regardless of the fact that the body 16 is cylindrical (with a constant cross-section) or conical (and thus has a variable cross-section).

[0031] The circumferential ribs have the functions of protecting, supporting, and reinforcing the filtering member 18, while the longitudinal ribs 20 have the dual functions of ensuring the resistance of the filtering element 1 (to both bending and torsion), thus allowing it to be handled and introduced into one of the conduits (50, 60) of the cooling system; the ribs allow avoiding any collapse of the conduit 60 of the filtering member 18, so as to ensure an appropriate outflow volume of the filtered fluid. Advantageously, the longitudinal ribs 20 contact the inner wall 61 of the conduit 60, so as to directly cooperate with the inner wall 61, thus acting as an element for spacing the conduit from the filtering member 18 and as an element for supporting the filtering part 4 in the conduit 60.

[0032] At the same time, the distance generated by the longitudinal ribs 20 between the inner wall 61 of the conduit 60 and the filtering member 18 present at the opening 17 allows defining a flow passage between the filtering member and the inner wall. Therefore, when a fluid (which is used to cool the cooling system equipped with the filtering element 1) circulates in the filtering element 1, the (filtered) fluid can flow out from the opening 17 and flow along the opening 17 and along the wall 61 of the conduit 60 to the outside of the filtering part 4.

[0033] The conduits 50 and 60 are also fitted onto the cylindrical connecting parts 5A and 5B due to the tapered ends 8 of the cylindrical connecting parts 5A and 5B that taper towards the inside of each conduit, and this facilitates the superposition of the conduits 50 and 60 on the connecting parts.

[0034] The conduits 50 and 60 are fitted onto the cylindrical connecting parts 5A and 5B until they contact the collar 6, and the collar 6 thus acts as a depth reference for the correct fitting of the conduits.

[0035] Obviously, the connection between the conduits 50 and 60 and the cylindrical connection parts 5A and 5B can be implemented in any known way, not only by interference on the parts 5A and 5B (for example, by using elements such as clamps to fasten the conduit to the connection part).

[0036] The rigid body 5 of part 3 and the rigid body 16 of part 4 form a single body without interruption. The body is obtained by molding using a plastic material. The filter member is co-molded with parts 3 and 4 (i.e., molded in the same mold), and thus parts 3 and 4 are embedded in the filter member 18. In particular, parts 3 and 4 are molded on the filter member 18 when the (plastic) material defining the filter member has just been molded, so as to physically bond to the filter member and form a single element or body with it.

[0037] Alternatively, the filter member 18 is obtained by co-molding with the formation of the body (16), and thus is obtained directly during the molding of parts 3 and 4 of the body 2 of the filter element. Thus, even in this case, the body 2 is made of a single piece, and in this case, it is also manufactured as a single component: the filter member 18 is part of part 4 and its rigid body 16.

[0038] However, in the case where the body 2 is obtained by co-molding the filter member 18 and parts 3 and 4, and even in the case where the body is obtained by a single molding operation, the filter element 1 is manufactured as a single piece, and the parts defining the filter element 1 together form a single piece.

[0039] The filter element 1 is open at its end 26, and the end 26 is located at the cylindrical connection part 5A of the constraint part 3. The filter part 4 has an end 27 remote from the constraint part, and in Figures 1 to 3 the embodiment, this end 27 is closed by a closing part 28.

[0040] To avoid fluid stagnation and optimize the filtration and flow efficiency in the cooling system in which the filter element 1 is arranged, the closing part 28 has a conical or frustoconical shape facing the constraint part 3 (as shown in the drawings). In this way, the closing part 28 helps the cooling fluid circulating in the cooling system to flow out from part 4, because the fluid is guided towards the opening 17 and there is no stagnation at the closing part 28 in the filter element. Figure 3 )

[0041] Figure 4 and Figure 5 shows a first variant of the present invention. In these drawings, the parts corresponding to the parts in the previously described drawings are denoted by the same reference numerals.

[0042] The solution discussed is different fromFigures 1 to 3 The solution is because of the following fact: The filtering member 18 is not flat (as in Figures 1 to 4 ), but is corrugated, i.e., wavy. This increases the filtering surface of the filtering element 1 without increasing the overall size of the filter.

[0043] Similarly in Figure 4 and Figure 5 cases, the filtering member 18 forms a single element with the rigid body 16 of the filtering part 4 (and wherein, the rigid body 5 of the constraint part 3 is manufactured as a single piece with the above-mentioned one 16). Preferably, as described above, the filtering member is co-molded with the body 16.

[0044] In the drawings under discussion, considering that the circumferential ribs 19 are not provided, the rigid body 16 only includes longitudinal ribs 20 protruding from the filtering member 18. The window 17 (for the flow of the filtered fluid) is thus larger than Figure 1 the window of the solution.

[0045] Figure 6 and Figure 7 show another variant of the present invention. Similarly in this case, the components corresponding to the components in the previously described drawings are defined by the same reference numerals.

[0046] In the solution under discussion, the closing element 28 (still being part of the body 16, like the closing element in the previously described drawings) is in a cross shape and has an opening 35 between its rigid arms 36. The closing element is lined internally by the filtering member 18 (flat), and thus it contributes to the filtering of the cooling fluid in the longitudinal direction of the filtering element 1. The filtering member 18 is manufactured as a single piece with the rigid bodies 5 and 16, as in the above solution.

[0047] Figures 8 to 11 show another variant of the present invention. In these drawings, the components corresponding to the components in the previously described drawings are denoted by the same reference numerals.

[0048] In the solution under discussion, the filtering element 1 includes a hollow tubular body 2 (provided with a filtering part 4) inserted into an (outer) tubular element 80. The outer tubular element 80 is manufactured as a single piece with the first part 3 of the tubular body 2 of the filtering element, and it has an inner wall 81 spaced apart from the filtering member 18 and the ribs 20, so as to form an annular cavity 82 between the tubular body 2 and the outer tubular element 80, and the fluid is supplied to the annular cavity 82 after passing through the filtering element 18.

[0049] An outer tubular element 80 coaxial with the hollow tubular body 2 houses and protects the body 2; essentially, the tubular element is an extension of the portion 3 of the tubular body 2. The tubular element 80 corresponds to the connecting portion 5B of the body 5 described above (e.g. with respect to Figures 1 to 3 ), and a conduit 60 ( Figures 8 to 11 not shown in

[0050] ) can be fitted onto the tubular element 80, similar to the case of the connecting portion 5B.

[0051] The present invention allows to obtain a filter element 1 having a filtering surface greater than the portion 4, which can be inserted into conduits 50 and 60 of a battery cooling system, particularly (but not exclusively or necessarily) for a vehicle, without the need for any housing to accommodate it. The filter element 1 is directly inserted into one of the above-mentioned conduits, and in particular, its filtering portion 4 is shaped to prevent the conduit 60 in which the filtering member is inserted from collapsing, and to maintain a space for the circulation of the fluid during filtering between the filtering member and the internal portion of the conduit.

[0052] All this does not require the use of a housing that houses the filtering portion to line the filtering portion.

[0053] However, other solutions with the characteristics of the present invention as described by the appended claims can be provided according to the above description.

Claims

1. A filter element adapted for use in a fluid recirculation system for an air conditioning system, such as a system for cooling a battery assembly, the filter element (1) comprising a hollow tubular body (2) having a hollow tubular end portion (3) connected to a filter portion (4), the filter portion (4) having a hollow tubular body (16), there being a filter member (18) associated with the hollow tubular body (16), the tubular bodies (16) of the hollow end portion (3) and the filter portion (4) being connected to each other without interruption, the filter member (18) and the hollow end portion (3) and the hollow tubular body (16) forming a single body, characterized in that, The hollow tubular end portion (3) includes a tubular rigid body (5) having a radial outer collar (6) that divides the tubular rigid body into two portions (5A, 5B) adapted to cooperate directly with the conduits (50, 60) of the cooling system.

2. The filter element according to claim 1, wherein The portions (5A, 5B) of the tubular rigid body (5) terminate in end tapered ends (8) that define a step portion (11) with the respective portions (5A, 5B), and the hollow tubular body (16) of the filter portion (4) projects from one of these portions (5B).

3. The filter element according to claim 1, characterized in that, The tubular body (5) of the hollow tubular end portion (3) has a protruding portion (14) that is drilled (at 15).

4. The filter element according to claim 1, wherein, The hollow tubular body (16) of the filter portion includes protruding longitudinal ribs (20) that are made in one piece with the hollow tubular end portion (3) and are arranged around the filter element (18), and the longitudinal ribs (20) define the maximum diameter of the filter portion (4) in cross-section.

5. The filter element according to claim 4, characterized in that, The protruding longitudinal ribs (20) define the maximum diameter of the filter portion (4) in cross-section, and the maximum diameter is constant in each cross-sectional plane orthogonal to the longitudinal axis (W) of the filter portion and along that longitudinal axis.

6. The filter element according to claim 1, wherein The filter member (18) is co-molded with the end portion (3) and with the hollow tubular body (16) of the filter portion (4).

7. The filter element according to claim 1, characterized in that, The filter member (18) is part of the hollow tubular body (16) of the filter portion (4) and is obtained simultaneously during the molding of the hollow tubular body (16), and the body (2) of the filter element is a single molded part.

8. The filter element according to claim 1, wherein, The filter member (18) has a vacant surface arranged at the longitudinal opening (17) of the hollow tubular body (16).

9. The filter element according to claim 1, characterized in that, The hollow tubular body (16) of the filter portion (4) includes circumferential ribs (19) arranged above the filter member (18).

10. The filter element according to claim 1, characterized in that, The hollow tubular body (16) of the filter portion (4) has an end (27) remote from the hollow tubular end portion (3) and includes a closed portion (28) that is at least frustoconical in shape and faces the hollow tubular end portion (3).

11. The filter element according to claim 1, wherein The hollow tubular body (16) of the filter portion (11) has an end (27) remote from the hollow tubular end portion (3) and in the shape of a cross, the end (27) having an opening (35) and rigid arms (36), and the filter member is integrally joined to the end (27).

12. The element according to claim 1, characterized in that, The filter member is pleated.

13. The filter element according to claim 1, characterized in that, The hollow tubular end portion (3) includes a tubular element (80) which is externally superimposed around the filtering portion (4), and an annular chamber (82) is present between the filtering portion (4) and the inner wall (81) of the tubular element (80). The annular chamber (82) is adapted to receive the filtered fluid passing through the filtering portion (4), and the tubular element (80) superimposed on the filtering portion (4) directly cooperates with the conduit of the cooling system.

14. The filter element according to claim 1, wherein The hollow tubular body (16) of the filtering portion (4) alternatively has a cylindrical shape or a variable cross-section along the longitudinal axis (W) of the filtering portion (4).

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