Protective housing for a power electronic module, module comprising such a housing and its manufacturing method

Abstract

Protective housing for an electronic power module, module comprising such a housing and its manufacturing method The invention relates to a protective housing (1), in particular for an electronic power and / or electrical energy storage module (2), comprising a first part (3) and at least one second part (3') assembled at respective peripheral wings (3'') forming a jointing plane (PJ), the first (3) at least of said parts (3, 3') being made up of a metal body (4) comprising at least one liquid thermal regulation circuit (5) at least in one outer surface area.Protective housing (1) characterized in that said or each thermal regulation circuit (5) is formed by a plate (6) added in thermoplastic material, in that this plate (6) has a grooved pattern defining the grooves of the circulation channel or channels of the or each circuit (5) and in that this plate (6) is indirectly secured to said metal body (4) by a weld connection with an intermediate discontinuous or perforated thermoplastic layer (8), overmolded on the outer surface area concerned and having a grooved pattern matching the grooved pattern of the added thermoplastic plate (6). Figure to be published with the abstract: Fig. 1.

Description

Title of the invention: Protective housing for an electronic power module, module comprising such a housing and its manufacturing method

[0001] The present invention relates to the field of technical equipment for vehicles, in particular electric cars, and more particularly the protection and preservation of good operating conditions for the electrotechnical or electronic power equipment of these vehicles and / or the energy storage elements, and has as its subjects a protective housing (1) for an electronic power and / or electrical energy storage module (2), a module comprising such a housing, its manufacturing method and a vehicle comprising at least one such module.

[0002] The specific context of the invention is that of electronic power modules, in particular for electric cars, comprising a protective housing and at least one electronic power circuit, component or set of components, as well as possibly or alternatively electrical energy storage elements, housed in this housing. The latter is preferably sealed and forms a Faraday cage or enveloping shield, when at least one component or circuit is present, in order to meet the criteria in terms of electromagnetic compatibility with respect to its installation environment (in particular under the hood). Generally, these housings are formed of at least two constituent parts assembled together peripherally (preferably two parts). Such a construction makes it possible to protect the circuit(s), storage elements and / or component(s) from the external environment both physically and electromagnetically.

[0003] Known housings are generally composed of a casing and a metal cover (particularly made of aluminum) assembled together, and each produced by molding, stamping or mechanical welding. They include positioning and fixing sites for the electronic / electrical circuits / components to be housed, which are for example formed during the molding of the two parts of the housing.

[0004] Furthermore, at least one thermal regulation circuit is attached to one of the two parts to evacuate the calories generated by the operation of the aforementioned circuits and components, at least by those called power circuits, or even by the storage elements.

[0005] However, this thermal regulation function has not yet been carried out satisfactorily, due to a limited extension of the regulation means. thermal and their preferred realization in metal. Furthermore, when these means are made of another material, problems often arise in practical realization and reliability of the joining.

[0006] Furthermore, taking into account their method of production and the integration of the aforementioned positioning and fixing sites, the parts of these known housings comprise significant quantities of metallic material (high cost price, significant mass) and have variable wall thicknesses which do not allow heating or homogeneous thermal regulation of the part concerned.

[0007] The present invention aims to overcome at least some of these drawbacks.

[0008] To this end, the invention relates to a protective housing, in particular for a module power electronics and / or electrical energy storage, comprising at least two constituent parts assembled together peripherally, namely advantageously a first part and at least one second part assembled at the level of respective peripheral wings forming a jointing plane, the first at least of said parts being made up of a metallic body comprising at least one liquid thermal regulation circuit at the level of at least one external surface zone,

[0009] protective housing characterized in that said or each thermal regulation circuit is formed by an attached plate of thermoplastic material, in that this plate has a grooved pattern defining the grooves of the circulation channel or channels of the or each circuit and in that this plate is indirectly secured to said metal body by a weld connection with a discontinuous or perforated intermediate thermoplastic layer, overmolded on the outer surface area concerned and having a grooved pattern matching the grooved pattern of the attached plate of thermoplastic material.

[0010] The invention will be better understood from the following description, which relates to preferred embodiments, given as non-limiting examples, and explained with reference to the appended schematic drawings, in which:

[0011] [Fig-1] is a perspective view from below of an electronic power and / or electrical energy storage module comprising a protective housing according to a first embodiment of the invention;

[0012] [Fig.2] is a sectional view of the module shown [Fig.l];

[0013] [Fig.3] is a perspective view illustrating the construction of the regulation circuit thermal on the first constituent part of the protective housing shown in figures 1 and 2;

[0014] [Fig.4] is a perspective view from above of a power electronic module and / or electrical energy storage comprising a protective housing according to a second embodiment of the invention;

[0015] [Fig.5] is another perspective view of the module shown [Fig.4], the two constituent parts of the protective housing being separated;

[0016] [Fig.6] is a sectional view of the module shown [Fig.4];

[0017] [Fig.7A], [Fig.7B] and [Fig.7C] illustrate three successive stages of the process of production of the thermal regulation circuit on external surface areas of the first constituent part of the protective housing shown in figures 4 to 6;

[0018] [Fig.8] is a perspective view of the outer face of the first part constituting a protective housing according to a third embodiment of the invention, provided with a thermal regulation circuit;

[0019] [Fig.9] is a perspective view of the outer face of the first part constituting a protective housing according to a fourth embodiment of the invention, provided with two independent thermal regulation circuits;

[0020] [Fig. 10] is a perspective view of the outer face of the first constituent part of a protective housing according to a fifth embodiment of the invention, provided with three fluidically connected thermal regulation circuits;

[0021] [Fig. 11] is a perspective view of the outer face of the first constituent part of the protective housing of [Fig.l], further comprising a network (16) of interconnected reinforcing ribs and / or stiffening wings.

[0022] Figures 1 to 6 in particular illustrate a protective housing (1), in particular for an electronic power and / or electrical energy storage module (2), comprising at least two constituent parts (3, 3') assembled together peripherally, namely advantageously a first part (3) and at least one second part (3') assembled at respective peripheral wings (3”) forming a jointing plane (PJ), the first (3) at least of said parts (3, 3') being made up of a metal body (4) comprising at least one liquid thermal regulation circuit (5, 5', 5”) at least on one outer surface zone (4', 4”, 4”').

[0023] According to the invention, it is provided that the or each thermal regulation circuit (5, 5', 5”) is formed by a plate (6) added in thermoplastic material, that this plate (6) has a grooved pattern (7, 7', 7”, 7'”) defining the grooves of the circulation channel or channels of the or each circuit (5, 5', 5”) and that this plate (6) is secured indirectly to said metal body (4) by a weld connection with an intermediate discontinuous or perforated thermoplastic layer (8), overmolded on the outer surface area (4', 4”, 4'”) concerned and having a grooved pattern (9, 9', 9”, 9”') matching the grooved pattern (7, 7', 7”, 7”') of the added thermoplastic material plate (6).

[0024] The or each circulation channel of the or each liquid thermal regulation circuit (5, 5', 5”) is thus formed by mutual cooperation i) of the grooves of the pattern grooved (7, 7', 7”, 7”') of the attached thermoplastic material plate (6), ii) the coincident grooves (absence of molded material) of the grooved pattern (9, 9', 9”, 9'”) of the discontinuous intermediate thermoplastic layer (8) and iii) the relevant outer surface area (4', 4”, 4”') of the constituent part (3) of the housing (1).

[0025] The implementation of a securing interface (the discontinuous or perforated intermediate thermoplastic layer (8), which also participates in the production of the channels or conduits for circulation of the heat transfer liquid, makes it possible to guarantee a sealed and resistant securing, on the one hand, with the relevant external surface of the constituent part (3) of the housing (1) - the layer (8) being locally overmolded in the manner of a bead capable of following a 3D surface geometry and possibly consisting of a material specifically adapted to this function -, and, on the other hand, with the plate of thermoplastic material (6), for which it acts as a bonding primer, in a thermoplastic material compatible for the production of an assembly by welding and allowing a certain tolerance during the assembly process (without compromising the quality of the assembly).The thermoplastic materials of the layer (8) and the plate (6) are at least compatible with each other for welding purposes, but not necessarily identical.

[0026] In addition to the coincident strips of thermoplastic material, defining the grooved patterns of the layer (8) and the plate (6) and assembled together to form the channels of the or each liquid thermal regulation circuit (5, 5', 5”), the layer (8) and the plate (6) also each comprise, on their periphery, a continuous strip of thermoplastic material, the mutual assembly of which provides a peripheral seal to the corresponding circuit (5, 5', 5”).

[0027] The implementation, for the production of the or each thermal regulation circuit, of a plate (6) made of thermoplastic material, having in any case a lower thermal conduction than the metal forming the body (4), makes it possible to promote the thermal exchange between the thermal regulation fluid and the interior of the housing (1) with respect to the external environment, or even to isolate the thermal regulation circuit(s) (5, 5', 5”) with respect to the external environment when said thermoplastic material has specific thermal insulation properties.

[0028] The protective housing (1) according to the invention preferably forms a sealed container and advantageously also a Faraday cage or enveloping shield, the second or other constituent part(s) (3') and the peripheral assembly of said parts having characteristics adapted to this effect.

[0029] Advantageously, and as illustrated by way of examples in the attached figures, the first constituent part (3) corresponds to a casing in the form of a hollow shell or comprising several hollow shapes, defining a part or even the majority of the interior volume of the housing (1) and intended to receive the electronic components of power (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements.

[0030] In accordance with an important characteristic of the invention, the fixing zones (10) of the discontinuous intermediate thermoplastic layer (8) at the level of the outer surface zone(s) (4', 4”, 4'”) concerned of the metal body (4) have a surface condition promoting the joining by mechanical attachment and / or by chemical adhesion of said intermediate thermoplastic layer (8) with the metal body (4).

[0031] The surface condition promoting the adhesion or the joining of the overmolded thermoplastic material at the level of the or each external surface (4', 4”, 4”') of the metal body (4), improved mechanical strength and sealing, can result from a treatment by laser micro-grooving (see for example US 11745295) or from a chemical treatment of the passivation, phosphating, plasma treatment or anodization type.

[0032] The or each external surface (4', 4”, 4”') may advantageously have a flat or slightly curved shape, or at least a shape allowing the performance of a surface treatment of the aforementioned type and the sealed joining of the intermediate, discontinuous or perforated, overmolded thermoplastic layer (8).

[0033] Preferably, the thermoplastic material of the plate (6) and that of the discontinuous intermediate layer (8) are of a chemically compatible nature, preferably identical, and both advantageously consist of a material chosen from thermoplastic materials, possibly incorporating reinforcing fillers of the fiber or similar type, such as for example polypropylene or a material from the family of polyamides or polyketones.

[0034] In accordance with a first variant embodiment of the invention, illustrated for example in Figures 1 and 11, the housing (1) comprises a single thermal regulation circuit (5) formed on an outer surface area (4') by superimposed cooperation of a plate (6) made of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said flat outer surface area (4'), this outer surface area (4') corresponding to the bottom of an internal region (3'”) sunken or depressed, in particular with respect to the joint plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the major part of the interior volume of said housing (1).

[0035] In accordance with a second variant embodiment of the invention, illustrated for example in [Fig. 8], the housing (1) comprises a single thermal regulation circuit (5) arranged on at least two contiguous external surface zones (4', 4'”), this circuit (5) being formed by superimposed cooperation of a plate (6) made of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or openwork with said external surface areas (4' and 4”'), one (4') of these external surface areas (4') corresponding to the bottom of an internal region (3'”) sunken or depressed, in particular with respect to the jointing plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the major part of the internal volume of said housing (1).

[0036] In accordance with a third variant embodiment of the invention, illustrated for example in [Fig.9], the housing (1) comprises at least two independent thermal regulation circuits (5, 5', 5”), arranged on the same external surface area (4') or on at least two different external surface areas (4', 4”, 4'”) and each formed by superimposed cooperation of a plate (6) made of thermoplastic material and an intermediate thermoplastic layer (8) which is discontinuous or perforated with said external surface area (4') or said external surface areas (4', 4”, 4”') concerned.

[0037] In accordance with a fourth variant embodiment of the invention, illustrated for example in Figures 6, 7 and 10, the housing (1) comprises at least two separate thermal regulation circuits (5, 5', 5”) fluidly connected to each other, these thermal regulation circuits (5, 5', 5”) being arranged on the same outer surface area (4') or on at least two different outer surface areas (4', 4”, 4”') and all being formed by superimposed cooperation of a single plate (6) made of thermoplastic material and a single intermediate thermoplastic layer (8) discontinuous or perforated with said outer surface area (4') or said outer surface areas (4', 4”, 4'”) concerned.

[0038] In the context of the third and fourth variants mentioned above, it may be provided that said at least two different external surface zones (4', 4”) are located in planes parallel to the jointing plane (PJ), but offset relative to the latter and possibly between them, and each correspond to the bottom of an internal region (3'”) that is sunk or depressed, in particular relative to the jointing plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the majority of the internal volume of said housing (1).

[0039] In the context of the second, third and fourth variants mentioned above, it may be provided that said at least two different external surface zones (4', 4”) located in planes parallel to the jointing plane (PJ) are connected to each other by an intermediate surface zone (4'”) inclined relative to the jointing plane (PJ), on which is possibly arranged at least one connecting conduit (5”) between thermal regulation circuits (5, 5', 5”) formed by superimposed cooperation of the plate (6) made of thermoplastic material and the discontinuous or perforated intermediate thermoplastic layer (8) concerned with said inclined external surface zone (4”).

[0040] In order to avoid any need to specifically provide fixing or positioning sites in any of the constituent parts (3, 3'), in particular in the first part (3), for example in the context of tedious additional operations, the housing (1) may comprise at least one, preferably several, part(s) (11, 11') for positioning and / or fixing electronic power components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements, the part(s) (11, 11') being made of a thermoplastic material and secured adhesively or by metal / thermoplastic welding to the inner face of the metal body (4) of the first constituent part (3).

[0041] Advantageously and as shown for example in Figures 2, 5 and 7A, the positioning and / or fixing parts (11, 11') comprise screw barrels (11) or similar support and fixing studs, attached by adhesive fastening or by metal / thermoplastic welding to the inner face of the part (4, 4') of the housing (2) concerned, or overmolded on this face. Some of these barrels or studs may optionally be connected by material bridges, facilitating their placement, reducing the number of parts and facilitating their manufacture (simultaneous manufacture of at least two barrels).

[0042] Alternatively or additionally, it may be provided that the positioning and / or fixing parts (11, 11') comprise at least one mounting plate (11') with feet, secured adhesively or by metal / thermoplastic welding with the inner face of the part (4, 4') of the housing (2) concerned, or formed by overmolding on this face.

[0043] The joining by metal / thermoplastic welding for joining the parts (11, 11') can for example be carried out by implementing the method described in document US 11745295.

[0044] The electronic power components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements are mounted in such a way on the part (4, 4') of the housing (2) that they are in direct contact with the internal face of the wall of the part (4, 4') of the housing (2) on which they are mounted, said part then having a hollow shape adapted to house them in cooperation with the other constituent part of the housing. A thermal regulation circuit (5, 5', 5”) can advantageously be provided on the opposite external face of this wall.

[0045] In relation to the practical implementation on site of the module (2) and its connection, the housing (1) advantageously comprises, and preferably at the level of the first constituent part (3), at least one passage opening (12) for the electrical connection of the electronic power components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements, intended to be housed in said housing (1), with the exterior.

[0046] As shown in Figures 2, 5 and 6, and still in relation to the connection of the module (2) to its installation site, the housing (1) may comprise either mounted on one side of the passage opening (12), a passage-forming means defining a passageway between the interior of the housing (1) and the exterior, or, arranged on either side of the passage opening (12), complementary passage-forming means (13 and 13') ensuring by mutual cooperation the creation of a passageway between the interior of the housing (1) and the exterior, the or each passage means (13, 13') being optionally secured to the housing (2) by at least one positioning and / or fixing part (11, 11'), respectively on the interior and / or exterior face(s) of the first constituent part (3).

[0047] The configuration and arrangement of the passage forming means or of the construction resulting from the cooperation of the means (13, 13') for forming a passage through the opening (12), advantageously make it possible to keep intact the electromagnetic shielding properties of the housing (1), when this is desired.

[0048] According to a preferred practical embodiment of the invention, the metal body (4) of the first constituent part (3) consists of a metal sheet, where appropriate formed, advantageously made of aluminum or a metal alloy, forming an open casing, with possibly one or more hollow shape(s) defining at least part of the interior volume of said housing (1), and the second constituent part (3') forming a casing cover, advantageously consists of a formed sheet, or a molded or mechanically welded part made of metal, preferably aluminum or a metal alloy, the jointing plane (PJ) formed by cooperating and coincident peripheral wings (3”) of the constituent parts (3 and 3') incorporating a seal, where appropriate capable of preserving electromagnetic protection.

[0049] When the weight and cost of the metal body (4) of the first constituent part (3) must be reduced, and may then result in an insufficient thickness to provide sufficient rigidity to the housing (1), it may be provided, as shown in [Fig. 11] by way of example, that at least the first constituent part (3) comprises a metal body (4) consisting of a formed thin sheet metal, overmolded with at least one plastic material which constitutes, at least on the outer face of said metal body (4), advantageously on each of the outer and inner faces of this body (4), a network (16) of interconnected reinforcing ribs and / or stiffening wings.

[0050] The pipettes (15, 15) for supplying and discharging the liquid from the thermal regulation circuit(s) (5, 5', 5”) can either be formed in one piece with the plate (6), or be attached to this plate (by welding or by a fixing means with the use of a seal), or even be formed with the openwork intermediate layer (8). In terms of shapes, they can each be straight or bent, indifferently from one another and depending for example on the connection possibilities of each.

[0051] Screw barrels (17) can also be formed by overmolding at the peripheral wings (3”) of the first constituent part (3) for the screw assembly of the two parts of the housing (1), if necessary at the same time as the perforated layer (8).

[0052] The invention also relates (figures 1, 2 and 4 to 6) to an electronic power and / or electrical energy storage module (2), comprising a protective housing (1) in which electronic power components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements, are mounted.

[0053] This module (2) is characterized in that the protective housing (1) is a protective housing as described above, possibly forming a Faraday cage or shield and preferably sealed, and in that the electronic power components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, are mounted in said housing (1) while being in contact with a portion of the wall of the housing (1) corresponding to an external surface area (4', 4”, 4'”) of the latter comprising at least one liquid thermal regulation circuit (5, 5', 5”).

[0054] The invention also relates to a motor vehicle, in particular an electric vehicle, characterized in that it comprises at least one electronic power and / or electrical energy storage module (2) as described above.

[0055] Finally, the invention also relates to a method for manufacturing an electronic power and / or electrical energy storage module, comprising a protective housing (1) in which electronic power components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements, are mounted, said protective housing (1) advantageously being a protective housing as described previously.

[0056] This method is characterized in that it consists of providing a first constituent part (3) consisting of a metal body (4) forming a casing and comprising at least one external surface area (4', 4”, 4'”) at least one liquid thermal regulation circuit (5, 5', 5”), mounting the electronic power components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, in said metal body (4) forming a casing and assembling a second metal constituent part (3') forming a cover with said first constituent part (3) by means of respective peripheral wings (3”) mutually coinciding, forming by cooperation a jointing plane (PJ), preferably with the interposition of a sealing gasket, so as to obtain a module (2) with a protective casing (1) advantageously forming a Faraday cage or shield and preferably waterproof.

[0057] In accordance with an important characteristic of the invention, and as shown more precisely in Figures 3 and 7, the or each thermal regulation circuit (5, 5', 5”) is produced by indirect attachment of a plate (6) made of thermoplastic material, which has a grooved pattern (7, 7', 7”, 7”') defining the grooves of the circulation channel or channels of the or each circuit (5, 5', 5”), with the or each of the outer surface zones (4', 4”, 4'”) concerned, this by means of an intermediate discontinuous or perforated thermoplastic layer (8), previously overmolded on the outer surface zone (4', 4”, 4”') concerned, having a grooved pattern (9, 9', 9”, 9'”) which coincides with that of the plate made of thermoplastic material (6) added and with which said plate (6) made of thermoplastic material is joined by welding with coincident superposition of their respective grooved patterns.

[0058] According to a preferred embodiment of the invention, also emerging from Figures 3 and 7, the production of the or each thermal regulation circuit (5, 5', 5”) comprises the steps of overmolding on the outer surface area (4', 4”, 4”') concerned a discontinuous or perforated thermoplastic layer (8), providing a grooved pattern (9, 9', 9”, 9'”) which coincides with that of the circulation channel or channels of the circuit(s) (5, 5', 5”), then adding to this overmolded thermoplastic layer (8) a plate (6) made of thermoplastic material which has a grooved pattern (7, 7', 7”, 7'”) defining the grooves of the circulation channel or channels of the or each circuit (5, 5', 5”), by positioning said plate (6) in a superimposed manner relative to said layer (8) and with their grooved patterns coinciding. respective, and to secure said plate (6) with said layer (8) by welding.

[0059] Advantageously, the manufacturing method may consist of carrying out, before overmolding the or each discontinuous intermediate thermoplastic layer (8), at least at the level of the fixing zones (10) of this or these intermediate thermoplastic layer(s) (8) on the outer surface zone(s) (4', 4”, 4”') concerned of the metal body (4), a preliminary operation of preparing the aforementioned zone(s) (4', 4”, 4”') making it possible to obtain a surface state promoting joining by mechanical attachment or by adhesion. chemical bonding of said intermediate thermoplastic layer (8) with the metal body (4). For this purpose, one of the treatments indicated above can be used.

[0060] Preferably, the manufacturing method may also consist, before mounting the electronic power components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, in the metal body (4) forming the casing, in producing one or more positioning and / or fixing parts (11, 11') made of thermoplastic material, overmolded or added and secured adhesively or by metal / thermoplastic welding with the inner face of the metal body (4) of the first constituent part (3).

[0061] The part(s) (11, 11') for positioning and / or fixing electronic power components (2') and / or electrical energy storage elements (2”), may possibly be overmolded on the inner face of the metal body (4) simultaneously with the layer (8) on the outer face of this body (4).

[0062] Finally, and in particular when the metal body (4) of the first part is thin, the manufacturing method may further consist, before, after or during the overmolding of the outer surface area (4', 4”, 4'”) concerned of the metal body (4) with the discontinuous or perforated layer (8) of thermoplastic material, providing the grooved pattern (9, 9', 9”, 9”'), in overmolding at least the outer face of said metal body (4), advantageously each of the outer and inner faces of this body (4), with at least one plastic material, preferably identical to that of the layer (8) so as to constitute a network (16) of interconnected reinforcing ribs and / or stiffening wings, outside the outer surface area (4', 4”, 4”') concerned.

[0063] A possible practical variant of a method for producing in two stages at least one circuit (5, 5', 5”) for liquid thermal regulation on the outer face of the metal body (4) forming the casing of the first constituent part (3) will be described in more detail below (see also figures 7A to 7C).

[0064] During a first step, the thermoplastic overmolding of an openwork layer or an intermediate bead (8) is carried out on the metal casing (4): mechanical adhesion forming a mechanical hold and a seal between the metal and the thermoplastic. This mechanical hold or improved adhesion is ensured by a local or global mechanical preparation of the surfaces of the metal casing (4) and / or by preparation in chemical baths, for example anodizing, or one of the other types of surface treatments mentioned herein.

[0065] The metal casing (4) can be placed in a suitable overmolding mold either at room temperature or preheated to a temperature below the melting temperature of the thermoplastic.

[0066] The thermoplastic is injected onto the metal casing in the mold to form the bead or the intermediate openwork layer (8) by making a deposit according to a pattern negative with respect to the pattern of the thermal regulation circuit(s) (5, 5', 5”) and using a quantity of energy proportional to the quantity of thermoplastic mass used (therefore limited).

[0067] Closing the injection mold on the metal casing (4) makes it possible to manage flatness defects and to ensure a more precise geometry of said intermediate bead (8).

[0068] The second step of the process consists of welding the thermoplastic material plate (6) onto the intermediate thermoplastic bead or openwork layer (8), using one of the various known welding processes, with a possible tolerance on the process settings.

[0069] Thanks to the prior overmolding of the injected bead or intermediate layer (8), the shapes can match the 3D relief of the metal casing (4), as shown in Figures 7A, 8 and 10 in particular.

[0070] Of course, the invention is not limited to the embodiments described and shown in the attached drawings. Modifications remain possible, in particular from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

Claims

1. Protective housing (1), in particular for an electronic power and / or electrical energy storage module (2), comprising at least two constituent parts (3, 3') assembled together peripherally, namely advantageously a first part (3) and at least one second part (3') assembled at respective peripheral wings (3”) forming a jointing plane (PJ), the first (3) at least of said parts (3, 3') being made of a metal body (4) comprising at least one liquid thermal regulation circuit (5, 5', 5”) at least in one outer surface area (4', 4”, 4”'), protective housing (1) characterized in that said or each thermal regulation circuit (5, 5', 5”) is formed by a plate (6) added in thermoplastic material, in that this plate (6) has a grooved pattern (7, 7', 7”, 7'”) defining the grooves of the circulation channel or channels of the or each circuit (5, 5',5”) and in that this plate (6) is indirectly secured to said metal body (4) by a weld connection with an intermediate thermoplastic layer (8) which is discontinuous or perforated, overmolded on the outer surface area (4', 4”, 4”') concerned and having a grooved pattern (9, 9', 9”, 9'”) matching the grooved pattern (7, 7', 7”, 7'”) of the added thermoplastic material plate (6).,

2. Protective casing (1) according to claim 1, characterized in that fixing zones (10) of the discontinuous intermediate thermoplastic layer (8) at the level of the outer surface zone(s) (4', 4”, 4'”) concerned of the metal body (4) have a surface condition promoting the joining by mechanical attachment and / or by chemical adhesion of said intermediate thermoplastic layer (8) with the metal body (4).

3. Protective casing (1) according to claim 1 or 2, characterized in that the thermoplastic material of the plate (6) and that of the discontinuous intermediate layer (8) are of a chemically compatible nature, preferably identical, and both advantageously consist of a material chosen from thermoplastic materials, possibly incorporating reinforcing fillers such as fibers or the like, such as for example polypropylene or a material from the polyamide or polyketone family.

4. Protective casing (1) according to any one of claims 1 to 3, characterized in that it comprises a single thermal regulation circuit (5) formed on an outer surface area (4') by superimposed cooperation of a plate (6) of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said outer surface area (4') which is flat, and in that this outer surface area (4') corresponds to the bottom of an internal region (3”) which is sunken or depressed, in particular with respect to the joint plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the major part of the interior volume of said casing (1).

5. Protective housing (1) according to any one of claims 1 to 3, characterized in that it comprises a single thermal regulation circuit (5) arranged on at least two contiguous external surface zones (4', 4'”), this circuit (5) being formed by superimposed cooperation of a plate (6) of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said external surface zones (4' and 4'”), and in that one (4') of these external surface zones (4') corresponds to the bottom of an internal region (3”') sunken or depressed, in particular with respect to the joint plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the major part of the internal volume of said housing (1).

6. Protective casing (1) according to any one of claims 1 to 3, characterized in that it comprises at least two independent thermal regulation circuits (5, 5', 5”), arranged on the same external surface area (4') or on at least two different external surface areas (4', 4”, 4'”) and each formed by superimposed cooperation of a plate (6) of thermoplastic material and an intermediate thermoplastic layer (8) which is discontinuous or perforated with said external surface area (4') or said external surface areas (4', 4”, 4'”) concerned.

7. Protective housing (1) according to any one of claims 1 to 3, characterized in that it comprises at least two separate thermal regulation circuits (5, 5', 5”) fluidically connected to each other, these thermal regulation circuits (5, 5', 5”) being arranged on the same outer surface area (4') or on at least two different outer surface areas (4', 4”, 4”') and all being formed by superimposed cooperation of a single plate (6) of thermoplastic material and a single intermediate thermoplastic layer (8) discontinuous or perforated with said outer surface area (4') or said outer surface areas (4', 4”, 4'”) concerned.

8. Protective casing (1) according to any one of claims 6 and 7, characterized in that said at least two different external surface zones (4', 4”) are located in planes parallel to the jointing plane (PJ), but offset relative to the latter and possibly between them, and each corresponds to the bottom of an internal region (3'”) sunken or depressed, in particular relative to the jointing plane (PJ), of the metal body (4'), the latter forming a hollow and open casing, defining the major part of the internal volume of said casing (1).

9. Protective casing (1) according to any one of claims 6 to 8, characterized in that said at least two different outer surface zones (4', 4”) located in planes parallel to the jointing plane (PJ) are connected to each other by an intermediate surface zone (4”') inclined relative to the jointing plane (PJ), on which is optionally arranged at least one connecting conduit (5'”) between thermal regulation circuits (5, 5', 5”) formed by superimposed cooperation of the plate (6) made of thermoplastic material and the discontinuous or perforated intermediate thermoplastic layer (8) concerned with said inclined outer surface zone (4”').

10. Protective housing (1) according to any one of claims 1 to 9, characterized in that it comprises at least one, preferably several, part(s) (11, 11') for positioning and / or fixing electronic power components (2') and / or elements (2”) for storing electrical energy, the part(s) (11, 11') being made of a thermoplastic material and secured adhesively or by metal / thermoplastic welding with an inner face of the metal body (4) of the first constituent part (3).

11. Protective housing (1) according to claim 10, characterized in that the positioning and / or fixing parts (11, 11') include screw barrels (11) or support and fixing studs, attached by adhesive bonding or by metal / thermoplastic welding on the inner face of the metal body (4) of the constituent part (3) of the housing (2) concerned, or overmolded on this face.

12. Protective housing (1) according to claim 10, characterized in that the positioning and / or fixing parts (11, 11') comprise at least one mounting plate (11') with feet, secured adhesively or by metal / thermoplastic welding with the inner face of the metal body (4) of the constituent part (3) of the housing (2) concerned, or formed by overmolding on this face.

13. Protective housing (1) according to any one of claims 1 to 12, characterized in that it comprises, preferably at the level of the first constituent part (3), at least one passage opening (12) for the electrical connection of the electronic power components (2') and / or the electrical energy storage elements (2”), intended to be housed in said housing (1), with the exterior.

14. Protective housing (1) according to claim 13 and any one of claims 10 to 12, characterized in that it comprises either, mounted on one side of the passage opening (12), a passage-forming means defining a passageway between the interior of the housing (1) and the exterior, or, arranged on either side of the passage opening (12), complementary passage-forming means (13 and 13') ensuring by mutual cooperation the creation of a passageway between the interior of the housing (1) and the exterior, the or each passage means (13, 13') being optionally secured to the housing (2) by at least one positioning and / or fixing part (11, 11'), respectively on the interior and / or exterior face(s) of the first constituent part (3).

15. Protective housing (1) according to any one of claims 1 to 14, characterized in that the metal body (4) of the first constituent part (3) consists of a metal sheet, where appropriate formed, advantageously made of aluminum or a metal alloy, forming an open casing, with possibly one or more hollow shape(s) defining at least one part of the interior volume of said housing (1), and in that the second constituent part (3') forming a casing cover, advantageously consists of a formed sheet metal, or a molded or mechanically welded part made of metal, preferably aluminum or a metal alloy, the jointing plane (PJ) formed by cooperating and coincident peripheral wings (3”) of the constituent parts (3 and 3') incorporating a seal, where appropriate capable of preserving electromagnetic protection.

16. Protective housing (1) according to any one of claims 1 to 15, characterized in that at least the first constituent part (3) comprises a metallic body (4) consisting of a formed thin sheet, overmolded with at least one plastic material which constitutes, at least on the outer face of said metallic body (4), advantageously on each of the outer and inner faces of this body (4), a network (16) of interconnected reinforcing ribs and / or stiffening wings.

17. Electronic power and / or electrical energy storage module (2), comprising a protective housing (1) in which are mounted electronic power components (2') and / or electrical energy storage elements (2”), module (2) characterized in that the protective housing (1) is a protective housing according to any one of claims 1 to 16, possibly forming a Faraday cage or shield and preferably sealed, and in that the electronic power components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, are mounted in said housing (1) while being in contact with a wall portion of the housing (1) corresponding to an outer surface area (4', 4”, 4”') of the latter comprising at least one liquid thermal regulation circuit (5, 5', 5”).

18. Motor vehicle, in particular electric vehicle, characterized in that it comprises at least one electronic power and / or electrical energy storage module (2) according to any one of claims 1 to 17.

19. Method for manufacturing an electronic power and / or electrical energy storage module, comprising a protective housing (1) in which electronic power components (2') and / or energy storage elements (2”) are mounted. electrical, said protective housing (1) being a protective housing according to any one of claims 1 to 16, method characterized in that it consists in providing a first constituent part (3) consisting of a metal body (4) forming a casing and comprising at least one external surface area (4', 4”, 4'”) at least one liquid thermal regulation circuit (5, 5', 5”), in mounting the power electronic components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, in said metal body (4) forming a casing and in assembling a second metal constituent part (3') forming a cover with said first constituent part (3) by means of respective peripheral wings (3”) which are mutually coincident, forming by cooperation a jointing plane (PJ), preferably with the interposition of a seal,so as to obtain a module (2) with a protective casing (1) advantageously forming a Faraday cage or shield and preferably waterproof.,

20. Manufacturing method according to claim 19, characterized in that the or each thermal regulation circuit (5, 5', 5”) is produced by indirect joining of a plate (6) made of thermoplastic material, which has a grooved pattern (7, 7', 7”, 7'”) defining the grooves of the circulation channel or channels of the or each circuit (5, 5', 5”), with the or each of the outer surface zones (4', 4”, 4'”) concerned, this by means of an intermediate discontinuous or perforated thermoplastic layer (8), previously overmolded on the outer surface zone (4', 4”, 4'”) concerned, having a grooved pattern (9, 9', 9”, 9'”) which coincides with that of the plate made of thermoplastic material (6) added and with which said plate (6) made of thermoplastic material is joined by welding with coincident superposition of their respective grooved patterns.

21. Manufacturing method according to claim 19 or 20, characterized in that the production of the or each thermal regulation circuit (5, 5', 5”) comprises the steps of overmolding on the outer surface area (4', 4”, 4'”) concerned a discontinuous or perforated thermoplastic layer (8), providing a grooved pattern (9, 9', 9”, 9'”) which coincides with that of the circulation channel or channels of the circuit(s) (5, 5', 5”), then adding on this overmolded thermoplastic layer (8) a plate (6) made of thermoplastic material which has a grooved pattern (7, 7', 7”, 7”') defining the grooves of the circulation channel or channels of the or each circuit (5, 5', 5”), by positioning said plate (6) in a superimposed manner relative to said layer (8) and with coincidence of their respective grooved patterns, and in securing said plate (6) with said layer (8) by welding.

22. Manufacturing method according to any one of claims 19 to 21, characterized in that it consists in carrying out, before overmolding the or each discontinuous intermediate thermoplastic layer (8), at least at the level of the fixing zones (10) of this or these intermediate thermoplastic layer(s) (8) on the outer surface zone(s) (4', 4”, 4'”) concerned of the metal body (4), a preliminary operation of preparation of the aforementioned zone(s) (4', 4”, 4”') making it possible to obtain a surface state promoting the joining by mechanical attachment or by chemical adhesion of said intermediate thermoplastic layer (8) with the metal body (4).

23. Manufacturing method according to any one of claims 19 to 22, characterized in that it consists, before mounting the electronic power components (2') and / or the electrical energy storage elements (2”), in the metal body (4) forming the casing, in producing one or more positioning and / or fixing parts (11, 11') made of thermoplastic material, overmolded or added and secured adhesively or by metal / thermoplastic welding with the inner face of the metal body (4) of the first constituent part (3).

24. Manufacturing method according to any one of claims 21 and 22, characterized in that it consists, before, after or during the overmolding of the outer surface area (4', 4”, 4”') concerned of the metal body (4) with the discontinuous or perforated layer (8) of thermoplastic material, providing the grooved pattern (9, 9', 9”, 9”'), in overmolding at least the outer face of said metal body (4), advantageously each of the outer and inner faces of this body (4), with at least one plastic material, preferably identical to that of the layer (8) so as to constitute a network (16) of reinforcing ribs and / or stiffening wings interconnected, outside the outer surface area (4', 4”, 4”') concerned.

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