Cooling module for a motor vehicle

Abstract

The invention relates to a cooling module (1) including a heat exchanger (3) comprising: - a bundle of tubes (31) including a plurality of tubes which are spaced apart from one another; - a collector box (32, 33) which is arranged at each end of the bundle of tubes (31), the collector box (32, 33) including a collector plate (34) and a cover (35) which covers the collector plate (34), the cooling module (1) further including a two-fluid heat exchanger (5) including: - a tray (51) on the inside; and - a bundle of tubes (52) made up of a plurality of tubes, the bundle of tubes (52) being arranged within the tray (51), the tray (51) being arranged on the outer face of a cover (35) of at least one collector box (32, 33), the cover (35) and the tray (51) being integral with one another.

Description

COOLING MODULE FOR MOTOR VEHICLE

[0001] The present invention relates to a cooling module comprising in particular a heat exchanger for an electric or hybrid motor vehicle.

[0002] A cooling module of a motor vehicle conventionally comprises at least one heat exchanger and a ventilation device adapted to generate an air flow in contact with the at least one heat exchanger. The ventilation device thus makes it possible, for example, to generate an air flow in contact with the heat exchanger, when the vehicle is stationary or at low driving speed.

[0003] Conventionally, the heat exchanger is then placed in a compartment opposite at least one cooling bay, formed for example in the front face of the body of the motor vehicle. Depending on the different vehicles, this compartment may be more or less cluttered and obstacles may be present at the rear of the cooling module and hinder the evacuation of the air flow passing through it. This is particularly the case when the air flow is generated by the ventilation device.

[0004] In addition, the heat exchanger is generally connected to a thermal management circuit comprising various elements such as other heat exchangers, at least one pump or compressor, one or more expansion devices, valves as well as pipes of a heat transfer fluid.

[0005] The architectures of such a thermal management circuit can be numerous depending on the operating modes required as well as the elements whose thermal management is necessary, such as the passenger compartment, the batteries or even the powertrain. Such circuits with all of their elements thus take an important place within the motor vehicle.

[0006] One of the aims of the present invention is therefore to remedy at least partially the drawbacks of the prior art and to propose a heat exchanger, in particular for a cooling module, allowing easier integration within the motor vehicle.

[0007] The present invention therefore relates to a cooling module for a motor vehicle comprising a heat exchanger, said heat exchanger comprising: - a bundle of tubes comprising a multitude of tubes in which a heat transfer fluid is intended to circulate and arranged spaced apart from each other, a flow of air being intended to circulate between said tubes, - a collector box arranged at each end of the tube bundle, said collector box comprising a collector plate crossed by the tubes of the tube bundle and a cover covering said collector plate so as to form a cavity into which one end of the tubes opens, the cooling module further comprising a two-fluid heat exchanger comprising: - a tank inside which a first heat transfer fluid is intended to circulate, and - a bundle of tubes formed from a multitude of tubes inside which a second heat transfer fluid is intended to circulate between the two ends of the tubes, said bundle of tubes being arranged within the tank, the tank of the two-fluid heat exchanger being arranged on the external face of a cover of at least one manifold of the heat exchanger (3), the cover and the tank being made of one material from each other.

[0008] According to one aspect of the invention, the cooling module further comprises at least one multi-way valve, said multi-way valve comprising a hollow valve body comprising at least one inlet orifice and at least two outlet orifices for a heat transfer fluid, said multi-way valve comprising a movable heat transfer fluid redirection device configured to redirect the heat transfer fluid from at least one fluid inlet to one or other of the heat transfer fluid outlets, said redirection device being arranged within the hollow valve body, said hollow valve body being arranged on the external face of a cover of a manifold of the heat exchanger, the hollow valve body and the cover being made of one material from each other.

[0009] According to another aspect of the invention, the hollow valve body is arranged side by side with the pan of the two-fluid heat exchanger.

[0010] According to another aspect of the invention, a first outlet of the hollow valve body is an orifice provided in the cover of at least one manifold and opening into said manifold.

[0011] According to another aspect of the invention, the cooling module further comprises a pump for circulating a heat transfer fluid, said pump comprising a hollow pump body comprising a suction inlet and a discharge outlet for the heat transfer fluid, said pump comprising a device for circulating the heat transfer fluid connected to said hollow pump body, said hollow pump body being arranged on the external face of a cover of a manifold of the heat exchanger, the hollow pump body and the cover being made of one material from each other.

[0012] According to another aspect of the invention, the hollow pump body is arranged side by side with the tank of the two-fluid heat exchanger.

[0013] According to another aspect of the invention, the heat exchanger is surrounded by a frame forming an air guide for the air flow passing through said heat exchanger, the covers of the collector boxes forming at least one of the sides of said frame.

[0014] According to another aspect of the invention, the frame comprises a first integrated conduit connecting a heat transfer fluid outlet having passed through the tube bundle of the heat exchanger to the suction inlet of the pump.

[0015] According to another aspect of the invention, the frame comprises a second integrated conduit connecting a heat transfer fluid outlet of the multi-way valve to the suction inlet of the pump.

[0016] According to another aspect of the invention, the cooling module comprises: - a first collector housing arranged downstream of the heat exchanger in the direction of circulation of the air flow, said first collector housing comprising a volute and a tangential turbomachine, and - a second collector box located upstream of the heat exchanger.

[0017] Other characteristics and advantages of the present invention will appear more clearly on reading the following description, provided for illustrative and non-limiting purposes, and the appended drawings in which:

[0018] [Fig 1] Figure 1 shows a schematic perspective representation of a cooling module,

[0019] [Fig 2] Figure 2 shows a schematic perspective and sectional representation of the cooling module of Figure 1,

[0020] [Fig 3] Figure 3 shows a schematic perspective representation of a heat exchanger of the cooling module of Figure 1,

[0021] [Fig 4] Figure 4 shows a schematic representation in perspective and partially exploded of the heat exchanger of Figure 3,

[0022] [Fig 5] Figure 5 shows a schematic perspective representation of the heat exchanger of Figure 3 with a two-fluid heat exchanger and a multi-way valve,

[0023] [Fig 6] Figure 6 shows a schematic perspective and sectional representation of the heat exchanger of Figure 5 with a two-fluid heat exchanger and a multi-way valve,

[0024] [Fig 7] Figure 7 shows a schematic representation in perspective and partially exploded of the heat exchanger of Figure 5 with a two-fluid heat exchanger and a multi-way valve,

[0025] [Fig 8] Figure 8 shows a schematic perspective representation of the heat exchanger of Figure 3 with a two-fluid heat exchanger and a pump,

[0026] [Fig 9] Figure 9 shows a schematic perspective and sectional representation of the heat exchanger of Figure 8 with a two-fluid heat exchanger and a pump,

[0027] [Fig 10] Figure 10 shows a schematic representation in perspective and partially exploded of the heat exchanger of Figure 8 with a two-fluid heat exchanger and a pump,

[0028] [Fig 11] Figure 11 shows a schematic representation of a heat transfer fluid circuit.

[0029] In the different figures, identical elements bear the same reference numbers.

[0030] The following embodiments are examples. Although the description refers to one or more embodiments, this does not necessarily mean that each reference relates to the same embodiment, or that the features apply only to a single embodiment. Single features of different embodiments may also be combined and / or interchanged to provide other embodiments.

[0031] In this description, certain elements or parameters may be indexed, such as first element or second element, as well as first parameter and second parameter, or first criterion and second criterion, etc. In this case, it is a simple indexing to differentiate and name elements or parameters or criteria that are close, but not identical. This indexing does not imply a priority of one element, parameter or criterion over another and such names can easily be interchanged without departing from the scope of this description. This indexing also does not imply an order in time, for example, to assess this or that criterion.

[0032] In this description, "upstream" means that an element is placed before another in relation to the direction of circulation of an air flow. Conversely, "downstream" means that an element is placed after another in relation to the direction of circulation of a flow or fluid.

[0033] Figures 1 and 2 show a cooling module 1 comprising a heat exchanger 3. This cooling module 1 may in particular be intended to be arranged on the front of a motor vehicle so as to be crossed by an air flow.

[0034] In the example illustrated in Figures 1 and 2, the cooling module 1 comprises a first collector housing 11 arranged downstream of the heat exchanger 3 in the direction of circulation of the air flow. This first collector housing 11 more particularly comprises a volute 11a as well as a tangential turbomachine 11b. The cooling module 1 may also comprise a second collector housing 12 arranged upstream of the heat exchanger 3 so as to guide the air flow towards the heat exchanger 3.

[0035] The heat exchanger 3 more particularly comprises a tube bundle 31 (visible in FIG. 2) comprising a multitude of tubes in which a heat transfer fluid is intended to circulate. The tubes of the tube bundle 31 are arranged spaced apart from each other so that the air flow passing through the cooling module 1 circulates between said tubes. The heat exchanger 3 also comprises two manifolds 32, 33 arranged respectively at each end of the tube bundle 31. These collector boxes 32, 33 comprise a collector plate 34 (visible in figures 6 and 7) crossed by the tubes of the tube bundle 31. The collector boxes 32, 33 also comprise a cover 35 covering said collector plate 34 so as to form a cavity into which one end of the tubes opens.

[0036] According to a first embodiment illustrated in Figures 2 to 10, the tubes of the tube bundle 31 may be hollow fibers. Such hollow fibers are preferably made of a material resistant to the operating temperatures of the heat exchanger 3. The hollow fibers are for example made of a polymer material, in particular a plastic material, in particular comprising a polyamide. By way of non-limiting example, mention may be made of polyamide 11 or polyamide 12, known by the acronyms PAU and PA12. These hollow fibers replace the aluminum tubes, for example known from the prior art, by being lighter and less expensive than the aluminum tubes.

[0037] The hollow fibers can in particular be sized and arranged so as to improve the performance of the heat exchanger 3 and minimize its cost. This sizing and arrangement can be done by taking into account in particular the exchanged power, defined from the overall exchange coefficient of the heat exchanger 3, the length of all the hollow fibers, the internal hydraulic efficiency, and the external hydraulic efficiency.

[0038] The hollow fibers may in particular each have a very small internal diameter, i.e. less than a millimeter, for example between 0.6 mm and 1 mm. The hollow fibers preferably have a generally tubular shape. More specifically, the hollow fibers may have a circular or substantially circular cross-section. The hollow fibers may also have a thickness of between 50 μm and 100 μm.

[0039] In the tube bundle 31, the hollow fibers may be free, that is, they are not encapsulated in a material or a plate, nor arranged inside a tube or the like. They may thus be in direct contact, without intermediary, with the air flow passing through the heat exchanger 3.

[0040] The arrangement of the hollow fibers in the tube bundle 31 may be regular. This means that the hollow fibers are arranged in a constant pattern, as opposed to a random arrangement. The hollow fibers may, for example, be arranged parallel to one another. The hollow fibers are advantageously arranged with a constant pitch between them. Furthermore, the gap is maintained between the hollow fibers so that no hollow fiber touches another hollow fiber, and each can, individually, exchange heat with the heat transfer fluid as it passes through the tube bundle 31.

[0041] It is nevertheless quite possible to imagine a variant in which the arrangement of the hollow fibers is random and intermingled.

[0042] According to a second embodiment not shown, the heat exchanger 3 may comprise a bundle of flat tubes stacked on top of each other and separated by spacers.

[0043] The heat exchanger 3 may in particular be surrounded by a frame 37 forming an air guide for the air flow passing through said heat exchanger 3 and framing the edges of the tube bundle 31. The covers 35 of the collector boxes 32, 33 form at least one of the sides of said frame 37.

[0044] Still as illustrated in Figures 1 and 2, the cooling module 1 further comprises a dual-fluid heat exchanger 5. This dual-fluid heat exchanger 5 more particularly comprises a tank 51, inside which a first heat transfer fluid is intended to circulate, and a bundle of tubes 52 arranged within the tank 51. This first heat transfer fluid may in particular be water or glycolated water. The tank 51 may thus comprise an inlet 51a and an outlet 51b for the first heat transfer fluid. Said inlet 51a and outlet 51b are connected to a water circuit.

[0045] The tube bundle 52 of the two-fluid heat exchanger 5 is notably formed of a multitude of tubes inside which a second heat transfer fluid is intended to circulate between the two ends of the tubes. The tube bundle 52 is thus immersed in the first heat transfer fluid within the tank 51. This first heat transfer fluid therefore circulates between the tubes of the tube bundle 52.

[0046] As better visible in Figures 6 and 9, the two-fluid heat exchanger 5 comprises a cover 54 covering and closing the tank 51. The cover 54 comprises an inlet 54a and an outlet 54b of the second heat transfer fluid to which the ends of the tubes of the tube bundle 52 are connected. The second heat transfer fluid can in particular be the same heat transfer fluid circulating in the heat exchanger 3. The latter can thus be connected to the same thermal management circuit, for example a battery thermal management circuit in which the second heat transfer fluid is a dielectric fluid and in which the batteries are immersed in said dielectric fluid.

[0047] A collector plate 53 is in particular arranged at the ends of the tubes of the tube bundle 52 at the inlet 54a and outlet 54b of the cover 54 in order to isolate the first heat transfer fluid circulating within the tank 51 and the second heat transfer fluid circulating within the tube bundle 52. In Figures 6 and 9, for the sake of clarity, the tubes of the tube bundle 52 are shown partially and the elbow formed by the latter to join the collector plates 53 is not shown. Like the tubes of the heat exchanger 3, the tubes of the tube bundle 52 of the two-fluid heat exchanger 5 can also be hollow fibers.

[0048] The tray 51 of the two-fluid heat exchanger 5 is in particular arranged on the external face of a cover 35 of at least one manifold 32, 33 of the heat exchanger 3. More particularly, the cover 35 and the tray 51 are made of one material from each other. The fact that the tray 51 is arranged on the external face of a cover 35 allows in particular to group these elements together to save space for better integration within the motor vehicle. In addition, the tray 51 and the cover 35 coming from one material of the other, the latter can be produced simultaneously for example by molding.

[0049] As illustrated in more detail in Figures 5 to 7, the cooling module 1 may also comprise at least one multi-way valve 6, for example a three-way valve.

[0050] This multi-way valve 6 may thus comprise a hollow valve body 61 comprising at least one inlet orifice 61a and at least two outlet orifices 61b, 61c for a heat transfer fluid. The multi-way valve 6 comprises a movable heat transfer fluid redirection device 62 and is configured to redirect the heat transfer fluid from the at least one fluid inlet 61a to one or other of the heat transfer fluid outlets 61b, 61c. This redirection device may for example be movable by means of a rotary actuator. The redirection device 62 is more particularly arranged within the hollow valve body 61.

[0051] The hollow valve body 61 can be arranged on the external face of a cover 35 of a manifold 32, 33 of the heat exchanger 3. As for the tank 51 of the two-fluid heat exchanger 5, the hollow valve body 61 and the cover 35 can be made from one material of the other.

[0052] The fact that the hollow valve body 61 is arranged on the external face of a cover 35 makes it possible in particular to group these elements together to save space for better integration within the motor vehicle. In addition, the hollow valve body 61 and the cover 35 being made from one material of the other, the latter can be produced simultaneously, for example by molding.

[0053] The hollow valve body 61 can more particularly be arranged on the same cover as the tray 51 of the two-fluid heat exchanger 5 side by side with the latter. This arrangement makes it possible in particular to reduce the size of the cooling module 1 and of these elements.

[0054] As illustrated in Figure 6, a first outlet 61b of the hollow valve body 61 may in particular be an orifice provided in the cover 35 of the at least one manifold 32, 33. This orifice opens into said manifold 32, 33 and allows the circulation of the heat transfer fluid from the multi-way valve 6 to the manifold 32, 33.

[0055] The multi-way valve 6 can in particular be connected to the same thermal management circuit as the heat exchanger 3. Thus, the heat transfer fluid intended to circulate in the heat exchanger 3 and in the multi-way valve 6 is the same. The orifice of the first outlet 61b thus allows a direct connection between the multi-way valve 6 and the manifold 32, 33 and makes it possible to avoid the use of a pipe or a conduit to fluidically connect the multi-way valve 6 and the manifold 32, 33 and therefore makes it possible to reduce the assembly costs as well as the size.

[0056] As illustrated in more detail in Figures 8 to 10, the cooling module 1 may also comprise a pump 7 for circulating a heat transfer fluid. This pump 7 comprises a hollow pump body 71 comprising a suction inlet 71a and an outlet 71b for discharging the heat transfer fluid. This hollow pump body 71 may in particular have a volute shape, the outlet of the volute corresponding to the outlet 71b for discharging the heat transfer fluid.

[0057] The pump 7 also comprises a device 72 for circulating the heat transfer fluid connected to said hollow pump body 71, for example a wheel with blades arranged within the volute formed by the hollow pump body 71 and driven by an electric actuator.

[0058] The hollow pump body 71 can be arranged on the external face of a cover 35 of a collector box 32, 33 of the heat exchanger 3. The hollow pump body 71 and the cover 35 can in particular come from one material of the other.

[0059] The fact that the hollow pump body 71 is arranged on the external face of a cover 35 makes it possible in particular to group these elements together to save space for better integration within the motor vehicle. In addition, the hollow pump body 71 and the cover 35 being made from one material of the other, the latter can be produced simultaneously, for example by molding.

[0060] The hollow pump body 71 can be arranged side by side with the tank 51 of the two-fluid heat exchanger 5.

[0061] When the cooling module 1 comprises both a multi-way valve 6 and a pump 7, the hollow valve body 61 and the hollow pump body 71 can more particularly be arranged on the same cover 35 of a manifold 32, 33 on either side of the tank 51 of the two-fluid heat exchanger 5. These three elements are then combined on the same cover 35. It is nevertheless entirely possible to imagine several combinations of embodiments in which these elements are distributed over the two covers 35.

[0062] In order to limit the size and the assembly costs, the frame 37 comprises a first integrated pipe (not shown) connecting an outlet 3b of heat transfer fluid having passed through the bundle of tubes 31 of the heat exchanger 3 to the suction inlet 71a of the pump 7. This is particularly advantageous when the outlet 3b of heat transfer fluid having passed through the bundle of tubes 31 of the heat exchanger 3 and the pump 7 are arranged on manifold boxes 32, 33 arranged at opposite ends of the bundle of tubes 31.

[0063] Still in order to limit the size as well as the assembly costs, the frame 37 can also include a second integrated pipe (not shown) connecting an outlet 61b, 61c of heat transfer fluid from the multi-way valve 6 to the suction inlet 71a of the pump 7.

[0064] Figure 11 shows an example of a heat transfer fluid circuit A integrating both the heat exchanger 3, the bifluid heat exchanger 5, the pump 7 and the valve multi-way 6, here a three-way valve.

[0065] The heat transfer fluid circuit A can thus comprise a main loop A 1 comprising, in the direction of circulation of the heat transfer fluid, the pump 7, the two-fluid heat exchanger 5, a first heat exchanger with the batteries 8, the multi-way valve 6 and the heat exchanger 3. The heat transfer fluid outlet 71b of the pump 7 is here connected directly to the heat transfer fluid inlet 54a of the two-fluid heat exchanger 5 so that the heat transfer fluid passes into the tubes of its tube bundle 52.

[0066] The first heat exchanger with the batteries 8 can, for example, be a bath in which the battery cells are immersed. The heat transfer fluid is then a dielectric fluid.

[0067] As shown above, a first heat transfer fluid outlet 61b of the multi-way valve 6 is directly connected to the heat transfer fluid inlet of the heat exchanger 3. This can be achieved by an orifice provided in the cover 35 as described above in the description.

[0068] The heat transfer fluid circuit A here also comprises a first bypass line A2 connecting a second heat transfer fluid outlet 61c of the multi-way valve 6 to the suction inlet 71a of the pump 7. Both this second heat transfer fluid outlet 61c of the multi-way valve 6 and the heat transfer fluid outlet 3b of the heat exchanger 3 are connected to the suction inlet 71a of the pump 7.

[0069] The heat transfer fluid circuit A may also comprise a second bypass line A3 connected in parallel to the first heat exchanger with the batteries 8. This second bypass line A3 may in particular comprise a second heat exchanger 9 with the power electronics, the charger and / or the powertrain. An auxiliary pump 10, in particular having a function of blocking the heat transfer fluid when stopped, may also be arranged upstream of the first heat exchanger with the batteries 8.

[0070] The two-fluid heat exchanger 5 is also connected jointly to, for example, a cooling circuit B whose heat transfer fluid or refrigerant circulates within the tank 51 between the tubes of the tube bundle 52.

[0071] Thus, it is clear that by integrating a tank 51 of a two-fluid heat exchanger 5 directly onto a collector box 32, 33 of a heat exchanger 3, such a cooling module 1 can contain its size while facilitating its manufacture.

Claims

Claims

1. Cooling module (1) for a motor vehicle comprising a heat exchanger (3), said heat exchanger (3) comprising: - a bundle of tubes (31) comprising a multitude of tubes in which a heat transfer fluid is intended to circulate and arranged spaced apart from each other, a flow of air being intended to circulate between said tubes, - a collector box (32, 33) arranged at each end of the tube bundle (31), said collector box (32, 33) comprising a collector plate (34) crossed by the tubes of the tube bundle (31) and a cover (35) covering said collector plate (34) so ​​as to form a cavity into which one end of the tubes opens, characterized in that the cooling module (1) further comprises a two-fluid heat exchanger (5) comprising: - a tank (51) inside which a first heat transfer fluid is intended to circulate, and - a bundle of tubes (52) formed from a multitude of tubes inside which a second heat transfer fluid is intended to circulate between the two ends of the tubes, said bundle of tubes (52) being arranged within the tank (51), the tank (51) of the two-fluid heat exchanger (5) being arranged on the external face of a cover (35) of at least one manifold (32, 33) of the heat exchanger (3), the cover (35) and the tank (51) being made of one material from each other.

2. Cooling module (1) according to the preceding claim, characterized in that it further comprises at least one multi-way valve (6), said multi-way valve (6) comprising a hollow valve body (61) comprising at least one inlet orifice (61a) and at least two outlet orifices (61b, 61c) for a heat transfer fluid, said multi-way valve (6) comprising a redirection device (62) for the movable heat transfer fluid and configured to redirect the heat transfer fluid from the at least one fluid inlet (61a) to one or other of the heat transfer fluid outlets (61b, 61c), said redirection device (62) being arranged within the hollow valve body (61), said hollow valve body (61) being arranged on the external face of a cover (35) of a manifold (32, 33) of the heat exchanger (3), the hollow valve body (61) and the cover (35) being integral with each other.

3. Cooling module (1) according to claim 2, characterized in that the hollow valve body (61) is arranged side by side with the tank (51) of the two-fluid heat exchanger (5).

4. Cooling module (1) according to any one of claims 2 or 3, characterized in that a first outlet (61b) of the hollow valve body (61) is an orifice provided in the cover (35) of at least one manifold (32, 33) and opening into said manifold (32, 33).

5. Cooling module (1) according to any one of the preceding claims, characterized in that it further comprises a pump (7) for circulating a heat transfer fluid, said pump (7) comprising a hollow pump body (71) comprising a suction inlet (71a) and an outlet (71b) for discharging the heat transfer fluid, said pump (7) comprising a device (72) for circulating the heat transfer fluid connected to said hollow pump body (71), said hollow pump body (71) being arranged on the external face of a cover (35) of a manifold (32, 33) of the heat exchanger (3), the hollow pump body (71) and the cover (35) being made of one material from each other.

6. Cooling module (1) according to claim 5, characterized in that the hollow pump body (71) is arranged side by side with the tank (51) of the two-fluid heat exchanger (5).

7. Cooling module (1) according to any one of the preceding claims, characterized in that the heat exchanger (3) is surrounded by a frame (37) forming an air guide for the air flow passing through said heat exchanger (3), the covers (35) of the manifold boxes (32, 33) forming at least one of the sides of said frame (37).

8. Cooling module (1) according to claim 7 in combination with one of claims 2 to 4 and one of claims 5 or 6, characterized in that the frame (37) comprises a first integrated conduit connecting an outlet (3b) of heat transfer fluid having passed through the bundle of tubes (31) of the heat exchanger (3) to the suction inlet (71a) of the pump (7).

9. Cooling module (1) according to claim 7 in combination with one of claims 2 to 4 and one of claims 5 or 6 or according to claim 8, characterized in that the frame (37) comprises a second integrated conduit connecting a fluid outlet (61b, 61c) heat transfer fluid from the multi-way valve (6) to the suction inlet (71a) of the pump (7).

10. Cooling module (1) according to any one of the preceding claims, characterized in that it comprises: - a first collector housing (11) arranged downstream of the heat exchanger (3) in the direction of circulation of the air flow, said first collector housing (11) comprising a volute (11a) as well as a tangential turbomachine (11b), and - a second collector box (12) arranged upstream of the heat exchanger (3).

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