Heat exchange module interface comprising a heat shrinkable material

Abstract

The present disclosure provides "Heat exchange module interfaces including heat shrinkable material." A system for a motor vehicle can include a heat exchange module configured to transfer heat between a component of the motor vehicle and a fluid. The heat exchange module is fluidically coupled to a fluid passageway via an interface including heat shrinkable material. A method is also disclosed.

Description

Technical Field

[0001] This disclosure generally relates to battery packs for electrified vehicles, and more specifically to heat exchange modules and interfaces for said heat exchange modules. In this disclosure, the interfaces comprise heat-shrinkable materials. Background Technology

[0002] The need to reduce vehicle fuel consumption and emissions is well-known. Therefore, vehicles are being developed that reduce or completely eliminate reliance on internal combustion engines. Electrified vehicles are a type of vehicle developed for this purpose. Typically, electrified vehicles differ from conventional motor vehicles because they are selectively driven by electric motors powered by batteries. In contrast, conventional motor vehicles rely solely on internal combustion engines for propulsion.

[0003] High-voltage battery packs typically power the electric motors and other electrical loads of electric vehicles. A battery pack includes multiple battery cells and various other internal battery components that support the electric propulsion of the electric vehicle.

[0004] Battery cells generate heat during charging and discharging operations. Heat exchange plates (sometimes called "cold plates") are typically used to dissipate the heat generated by the battery cells. Summary of the Invention

[0005] In some respects, the technology described herein relates to a system for a motor vehicle comprising: a heat exchange module configured to transfer heat between components of the motor vehicle and a fluid, wherein the heat exchange module is fluidly coupled to a fluid channel via an interface comprising a heat-shrinkable material.

[0006] In some respects, the technology described herein relates to a system in which the interface includes a first port and a second port at least partially located within the first port, and the first port is made of a heat-shrinkable material.

[0007] In some respects, the technology described herein relates to a system in which the fluid channel includes the second port and the heat exchange module includes the first port.

[0008] In some respects, the technology described herein relates to a system in which the fluid channel includes the first port and the heat exchange module includes the second port.

[0009] In some respects, the technology described herein relates to a system in which the heat exchange module includes an inlet port, an outlet port, and a body portion, and the body portion includes an internal passageway fluidly connecting the inlet port to the outlet port.

[0010] In some respects, the technology described herein relates to a system in which the entire heat exchange module is made of a heat-shrinkable material.

[0011] In some respects, the technology described herein relates to a system in which the inlet port and the outlet port comprise a heat-shrinkable material, and the body portion is made of a material different from the heat-shrinkable material.

[0012] In some aspects, the technology described herein relates to a system in which an inlet port is configured to receive a flow of fluid via the inlet port, the inlet port being fluidly coupled to the fluid channel via a first interface comprising a heat-shrinkable material, an outlet port being configured to discharge a flow of fluid into the fluid channel, and the outlet port being fluidly coupled to the fluid channel via a second interface comprising a heat-shrinkable material.

[0013] In some respects, the technology described herein relates to a system in which the heat exchange module is a first heat exchange module among a plurality of heat exchange modules of the system, the fluid passage includes a manifold configured to dispense fluid relative to each of the plurality of heat exchange modules, and the interface between each of the heat exchange modules and the manifold includes a heat-shrinkable material.

[0014] In some respects, the technology described herein relates to a system in which the heat-shrinkable material is a polyolefin material.

[0015] In some respects, the technology described herein relates to a system in which the entire heat exchange module is made of polyolefin.

[0016] In some respects, the technology described herein relates to a system in which the motor vehicle is an electric vehicle, and the heat exchange module is arranged between battery cells within the battery array of the electric vehicle.

[0017] In some respects, the technology described herein relates to a system in which the heat exchange module is one of a tube, fin, or channel.

[0018] In some respects, the technology described herein relates to a system in which the component of the motor vehicle is a battery pack.

[0019] In some respects, the technology described herein relates to a system in which the interface includes an adhesive.

[0020] In some respects, the technology described herein relates to a method comprising: establishing a fluid-sealed connection between a fluid passage and a heat exchange module of a motor vehicle by applying heat to the interface between the fluid passage and the heat exchange module, wherein the interface comprises a heat-shrinkable material.

[0021] In some respects, the technology described herein relates to a method in which the interface includes a first port and a second port at least partially within the first port, and the first port is made of a heat-shrinkable material.

[0022] In some respects, the technology described herein relates to a method in which the fluid channel includes one of the first port or the second port, and the heat exchange module includes the other of the first port or the second port.

[0023] In some aspects, the technology described herein relates to a method in which the heat exchange module includes an inlet port, an outlet port, and a body portion, the body portion including an internal passage fluidly connecting the inlet port to the outlet port, and the method includes establishing a fluid-sealed connection between the fluid passage and the inlet port by applying heat to a heat-shrinkable material, and further includes establishing a fluid-sealed connection between the fluid passage and the outlet port by applying heat to a heat-shrinkable material.

[0024] In some respects, the technology described herein relates to a method in which the heat exchange module is a first heat exchange module of a plurality of heat exchange modules, the fluid passage includes a manifold configured to dispense fluid relative to each of the plurality of heat exchange modules, the method comprising establishing a fluid-tight connection between the manifold and each of the heat exchange modules by applying heat to an interface between each of the heat exchange modules and the manifold, and each of the interfaces comprising a heat-shrinkable material. Attached Figure Description

[0025] Figure 1 An exemplary powertrain system for an electrified vehicle is illustrated schematically.

[0026] Figure 2 This is a perspective view of an exemplary battery pack.

[0027] Figure 3 An exemplary arrangement of the fluid channels relative to the two heat exchange modules is shown.

[0028] Figure 4 An exemplary arrangement of the fluid channels relative to the heat exchange module is schematically shown.

[0029] Figure 5A An exemplary interface between the heat exchange module and the fluid channel is shown before heat is applied at the interface.

[0030] Figure 5B This shows the effect after heat is applied to the interface. Figure 5A The interface. Detailed Implementation

[0031] This disclosure generally relates to battery packs for electrified vehicles, and more specifically to heat exchange modules and interfaces for said heat exchange modules. In this disclosure, the interfaces comprise heat-shrinkable materials. In addition to other benefits that will become apparent from the description below, this disclosure also establishes a robust fluid connection between fluid channels and the heat exchange module.

[0032] Figure 1 The powertrain 10 of an electrified vehicle 12 is schematically shown. Although depicted as a battery electric vehicle (BEV), it should be understood that the concepts described herein are not limited to BEVs and can be extended to other electrified vehicles, including but not limited to plug-in hybrid electric vehicles (PHEVs). Therefore, although not shown in this embodiment, the electrified vehicle 12 may be equipped with an internal combustion engine, which may be used in combination with other energy sources to propel the electrified vehicle 12. Furthermore, aspects of this disclosure can be applied to vehicles that are not electrified, such as vehicles propelled solely by an internal combustion engine. As an example, the heat exchange module of this disclosure may be arranged between stacks of fuel cells.

[0033] In a non-limiting embodiment, the electrified vehicle 12 is a purely electric vehicle propelled solely by electricity (such as via motor 14) without any assistance from an internal combustion engine. Motor 14 may operate as an electric motor, a generator, or both. Motor 14 receives electrical power and provides rotational output power. Motor 14 may be connected to a gearbox 16 to adjust the output torque and speed of motor 14 at a predetermined gear ratio. Gearbox 16 is connected to a set of drive wheels 18 via an output shaft 20. A high-voltage bus 22 electrically connects motor 14 to a battery pack 24 via an inverter 26. Motor 14, gearbox 16, and inverter 26 may be collectively referred to as transmission 28.

[0034] Battery pack 24 is an exemplary battery for an electrified vehicle. Battery pack 24 may be a high-voltage traction battery pack, which includes multiple battery assemblies 25 (i.e., battery arrays or battery cell groups) capable of outputting power to operate the motor 14 and / or other electrical loads of the electrified vehicle 12. Other types of energy storage devices and / or output devices may also be used to power the electrified vehicle 12.

[0035] Figure 1 The powertrain system 10 shown is highly illustrative and is not intended to limit the scope of this disclosure. Alternatively or additionally, within the scope of this disclosure, the powertrain system 10 may employ various other components.

[0036] Figure 2Additional details of an exemplary battery pack 24 are shown. In this example, the battery pack 24 includes a housing assembly 30. The housing assembly 30 includes a cover 32 and a tray 34. In this example, the cover 32 is vertically above the tray 34. However, in other examples, the cover 32 may be arranged below or to the side of the tray 34. Various terms such as “above,” “below,” “top,” and “bottom” are used relative to the arrangement of the battery pack 24 in the various figures and should not be considered limiting in any other way.

[0037] In one example of this disclosure, the cover 32 is welded to the tray 34. Although welding is mentioned, the cover 32 and the tray 34 may be joined using other fluid-tight joining techniques, such as adhesives. Furthermore, while an exemplary housing assembly 30 is shown in the figures, the size, shape, and configuration of the housing assembly 30 may vary within the scope of this disclosure.

[0038] The cover 32 provides the top wall of the housing assembly 30. The tray 34 includes a bottom wall 38 opposite to the cover 32, a first side wall 40, a second side wall 42 opposite to the first side wall 40, a first end wall 44, and a second end wall 46 opposite to the first end wall 44. The walls 38, 40, 42, 44, and 46 of the tray 34 are configured to hold a battery array 48 (“array 48”).

[0039] The housing assembly 30 includes an inlet 50 and an outlet 52, the inlet being formed in a first sidewall 40 in this example, and the outlet also being formed in a first sidewall 40 in this example. Various hydraulic couplings may be provided relative to the inlet 50 and outlet 52. The hydraulic couplings together establish a fluid passage 49, which is a series of pipes, conduits, and sections that collectively form a continuous path for fluid flow. The fluid passage 49 is coupled to a fluid source S. The source S may be a reservoir. In this example, the fluid is coolant C. Coolant C may be referred to as a heat exchange fluid. The fluid passage 49 may be in fluid communication with one or more pumps P configured to pressurize coolant C.

[0040] Fluid passage 49 is configured to guide coolant C relative to array 48 to thermally regulate array 48, for example, by absorbing heat from array 48. Coolant C may be referred to as a heat exchange fluid. In this example, coolant C typically flows from source S to inlet 50, flows back to outlet 52 within housing assembly 30, and eventually flows back to source S.

[0041] In this disclosure, an array 48 of battery cells 25 is arranged within a battery pack 24. The battery cells 25 are typically stacked face-to-face to construct the array 48. Within the scope of this disclosure, the battery pack 24 can employ any number of battery cells 25. Figure 2In this configuration, every two battery cells 25 are separated by a heat exchange module 54. The heat exchange module 54 can be considered as part of the array 48.

[0042] In this example, heat exchange module 54 is configured as a heat exchange strip. As other examples, heat exchange module 54 may be configured as a tube, channel, or fin. Although in Figure 2 In this configuration, the heat exchange module 54 is located between adjacent battery cells 25. However, the heat exchange module 54 can be configured as a heat exchange plate, sometimes referred to as a "cold plate," and in this example, it can extend substantially the entire length of the array 48 and be arranged adjacent to the bottom, top, or side of each of the battery cells 25.

[0043] Figure 3 Two exemplary heat exchange modules 54A and 54B are shown relative to a portion of fluid channel 49. Figure 4 A heat exchange module 54A relative to fluid channel 49 is further shown. (Common Reference) Figure 3 and Figure 4 Heat exchange module 54A will now be described. Heat exchange module 54B and any other heat exchange module 54 may be arranged relative to fluid passage 49 in substantially the same manner as heat exchange module 54A.

[0044] The heat exchange module 54A includes an inlet port 60, an outlet port 62, and a body portion 64. In this example, the inlet port 60 and the outlet port 62 are arranged on one side of the heat exchange module 54A. The body portion 64 occupies most of the area of ​​the heat exchange module 54A. The body portion 64 includes an internal passage 66 that fluidly connects the inlet port 60 to the outlet port 62. Figure 4 The internal passage 66 is a hollow channel within the body portion 64 and can be arranged in any manner within the body portion 64, such as following a generally serpentine or tortuous path as an example. The body portion 64 can be formed by injection molding, additive manufacturing, or another known technique. In an embodiment, the body portion 64 is formed by attaching two separately formed halves using a technique such as welding.

[0045] Coolant C is guided to heat exchange modules 54A and 54B via fluid channel 49. Figure 3 In this embodiment, a portion of the fluid passage 49 is configured as a manifold 68. In this example, the manifold 68 is disposed within the housing assembly 30. The manifold 68 includes a first section 69 fluidly connected to an inlet 50 and configured to direct coolant C to heat exchange modules 54A, 54B via a first outlet port 70 and a second outlet port 72. The manifold 68 also includes a second section 74 configured to direct coolant C discharged from heat exchange modules 54A, 54B to an outlet 52 via a first inlet port 76 and a second inlet port 78.

[0046] The first outlet port 70 is configured to be fluidly connected to the inlet port 60 of the heat exchange module 54A via a first interface, and the first inlet port 76 is configured to be fluidly connected to the outlet port 62 of the heat exchange module 54A via a second interface. Similarly, the second outlet port 72 and the second inlet port 78 are configured to be fluidly connected to the inlet port 80 and outlet port 82 of the heat exchange module 54B via a third interface and a fourth interface, respectively. Similar interfaces exist between the manifold 68 and any other heat exchange module 54. Although the manifold 68 is shown, it is not required in all examples.

[0047] In this disclosure, the interface between the heat exchange module 54 and the fluid channel 49 comprises a heat-shrinkable material. Specifically, the interface between the inlet and outlet of the heat exchange module 54 and the corresponding outlet and inlet of the manifold 68 comprises a heat-shrinkable material.

[0048] Figure 4 and Figure 5B An exemplary interface 84 between inlet port 60 and outlet port 70 is shown. Exemplary interface 84 represents other interfaces between fluid passage 49 and heat exchange module 54. (See also...) Figure 4 and Figure 5B As shown, the outlet port 70 is partially arranged within the inlet port 60. In this respect, the inlet port 60 and the outlet port 70 may exhibit a common cross-sectional shape, such as a substantially circular cross-sectional shape, to facilitate the alignment of the inlet port 60 and the outlet port 70, as... Figure 5A As shown. This disclosure extends to other cross-sectional shapes of various inlet and outlet ports. Furthermore, although in this example a portion of outlet port 70 is within inlet port 60, in other examples the arrangement may be reversed, with a portion of inlet port 60 received within outlet port 70.

[0049] In this example, the inlet port 60 comprises a heat-shrinkable material, and specifically, the inlet port 60 is at least partially made of a heat-shrinkable material. In a particular example, the inlet port 60 is entirely made of a heat-shrinkable material. The body portion 64 may be made of a different material than the inlet port 60. However, in other examples, the body portion 64 may be made of a heat-shrinkable material. Specifically, the entire heat exchange module 54 may be integrally formed as a single integrated structure of heat-shrinkable material. In one example, the heat-shrinkable material is a polyolefin material.

[0050] Applying heat to the inlet port 60 causes the inlet port 60 to shrink relative to its original size. This can be achieved via the heat applicator 86 ( Figure 5BHeat is applied to the inlet port 60. The heat applicator 86 may include an attachment 88 configured to direct heat H to the inlet port 60 while preventing heat from being directed to the body portion 64. The outlet port 70, partially within the inlet port 60, is not made of a heat-shrinkable material, such that the outlet port 70 retains its shape when heat H is applied to the interface. When heat H is applied to the inlet port 60, the size of the inlet port 60 decreases, causing the inlet port 60 to seal against the outer wall of the outlet port 70. After the inlet port 60 shrinks, the heat-shrinkable material has no remaining stored elastic energy to drive it back to its original expanded shape. Thus, a fluid-sealed connection is established. An adhesive may be applied between the inlet port 60 and the outlet port 70 before the application of heat H to further facilitate the formation of the fluid-sealed connection.

[0051] It should be understood that terms such as “about,” “basically,” and “generally” are not intended to be unbounded terms and should be interpreted in accordance with the manner in which those skilled in the art would interpret those terms. It should also be understood that directional terms such as “upper,” “top,” “vertical,” “forward,” “rearward,” “side,” “above,” and “below” are used herein in relation to the normal operating posture of the vehicle for illustrative purposes only and should not be considered restrictive.

[0052] Although the different examples have the specific components shown in the illustrations, the embodiments of this disclosure are not limited to those particular combinations. Some components or features from one example may be used in combination with features or components from another example. In addition, the various drawings of this disclosure are not necessarily drawn to scale, and some features may be enlarged or minimized to show certain details of a particular component or arrangement.

[0053] Those skilled in the art will understand that the above embodiments are exemplary and not restrictive. That is, modifications to this disclosure will fall within the scope of the claims. Therefore, the appended claims should be studied to determine their true scope and content.

[0054] According to the present invention, a method includes: establishing a fluid-sealed connection between the fluid channel and the heat exchange module by applying heat to the interface between a fluid channel and a heat exchange module of a motor vehicle, wherein the interface comprises a heat-shrinkable material.

[0055] In one aspect of the invention, the interface includes a first port and a second port at least partially within the first port, and the first port is made of a heat-shrinkable material.

[0056] In one aspect of the invention, the fluid channel includes one of the first port or the second port, and the heat exchange module includes the other of the first port or the second port.

[0057] In one aspect of the invention, the heat exchange module includes an inlet port, an outlet port, and a body portion, the body portion including an internal passage fluidly connecting the inlet port to the outlet port, and the method includes establishing a fluid-sealed connection between the fluid passage and the inlet port by applying heat to a heat-shrinkable material, and further includes establishing a fluid-sealed connection between the fluid passage and the outlet port by applying heat to a heat-shrinkable material.

[0058] In one aspect of the invention, the heat exchange module is a first heat exchange module of a plurality of heat exchange modules, the fluid passage includes a manifold configured to dispense fluid relative to each of the plurality of heat exchange modules, the method comprising establishing a fluid-tight connection between the manifold and each of the heat exchange modules by applying heat to an interface between each of the heat exchange modules and the manifold, and each of the interfaces comprising a heat-shrinkable material.

Claims

1. A system for a motor vehicle, comprising: A heat exchange module configured to transfer heat between a component of the motor vehicle and a fluid, wherein the heat exchange module is fluidly connected to a fluid channel via an interface comprising a heat-shrinkable material.

2. The system of claim 1, wherein: The interface includes a first port and a second port that is at least partially located within the first port, and The first port is made of a heat-shrinkable material.

3. The system of claim 2, wherein the fluid channel includes the second port and the heat exchange module includes the first port.

4. The system of claim 2, wherein the fluid channel includes the first port and the heat exchange module includes the second port.

5. The system of claim 1, wherein: The heat exchange module includes an inlet port, an outlet port, and a main body. The main body includes an internal passage that fluidly connects the inlet port to the outlet port.

6. The system of claim 5, wherein the entire heat exchange module is made of a heat-shrinkable material.

7. The system of claim 5, wherein the inlet port and the outlet port comprise a heat-shrinkable material, and the body portion is made of a material different from the heat-shrinkable material.

8. The system of claim 5, wherein: The inlet port is configured to receive the flow of the fluid via the inlet port. The inlet port is fluidly connected to the fluid channel via a first interface comprising a heat-shrinkable material. The outlet port is configured to discharge the fluid into the fluid channel, and The outlet port is fluidly connected to the fluid channel via a second interface comprising a heat-shrinkable material.

9. The system of claim 1, wherein: The heat exchange module is the first heat exchange module among multiple heat exchange modules in the system. The fluid passage includes a manifold configured to dispense fluid relative to each of the plurality of heat exchange modules, and The interface between each of the heat exchange modules and the manifold comprises a heat-shrinkable material.

10. The system of claim 1, wherein the heat-shrinkable material is a polyolefin material.

11. The system of claim 10, wherein the entire heat exchange module is made of polyolefin.

12. The system of claim 1, wherein: The motor vehicle is an electric vehicle, and The heat exchange module is arranged between the battery cells within the battery array of the electric vehicle.

13. The system of claim 1, wherein the heat exchange module is one of a tube, a fin, or a channel.

14. The system of claim 1, wherein the component of the motor vehicle includes a battery pack.

15. The system of claim 1, wherein the interface comprises an adhesive.

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