Protective housing for a power electronics module, module comprising such a housing and method for manufacturing same

Abstract

The invention relates to a protective housing (1), in particular for a power electronics and / or electrical-energy storage module (2), comprising a first portion (3) and at least one second portion (3') which are assembled at respective peripheral flanges (3") forming a jointing plane (PJ), at least the first (3) of the portions (3, 3') consisting of a metal body (4) comprising, in at least one exterior-surface region, at least one liquid thermal regulation circuit (5). The protective housing (1) is characterized in that the or each thermal regulation circuit (5) is formed by an attached plate (6) made of a thermoplastic material, in that this plate (6) has a grooved pattern defining the grooves of the circulation channel(s) of the or each circuit (5) and in that this plate (6) is secured indirectly to the metal body (4) by a welded bond with a discontinuous or openwork intermediate thermoplastic layer (8), overmoulded onto the exterior-surface region concerned and having a grooved pattern consistent with the grooved pattern of the attached plate (6) made of a thermoplastic material.

Description

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

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

[0002] The specific context of the invention is that of electronic power modules, particularly for electric vehicles, comprising a protective housing and at least one electronic power circuit, component, or set of components, as well as optionally or alternatively electrical energy storage elements, housed within this housing. The housing is preferably sealed and forms a Faraday cage or enclosing shield, when at least one component or circuit is present, in order to meet electromagnetic compatibility requirements with its installation environment (particularly under the hood). Generally, these housings are formed of at least two constituent parts assembled 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] Typical enclosures generally consist of a metal casing and cover (often made of aluminum) assembled together, each manufactured by molding, stamping, or welding. They include positioning and mounting points for the electronic / electrical circuits / components to be housed, which are formed, for example, during the molding of the two enclosure parts.

[0004] In addition, at least one thermal regulation circuit is reported on 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 by the storage elements.

[0005] However, this thermal regulation function is not currently performed satisfactorily due to the limited range of thermal regulation devices and their preferential use in metal. Furthermore, when these devices are made of another material, practical implementation and reliability issues often arise.

[0006] Furthermore, given their method of manufacture and the integration of the aforementioned positioning and fixing sites, the parts of these known boxes contain significant quantities of metallic material (high cost price, significant mass) and have variable wall thicknesses which do not allow for 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 an electronic power and / or electrical energy storage module, comprising at least two constituent parts assembled together peripherally, namely advantageously a first part and at least a second part assembled at the level of respective peripheral wings forming a joining plane, the first at least of said parts being made of a metallic body comprising at least one external surface area at least one liquid thermal regulation circuit, the 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 channel or channels of circulation of the circuit or each circuit and in that this plate is indirectly joined to said metal body by a welded connection with a discontinuous or perforated intermediate thermoplastic layer, overmolded onto the relevant outer surface area and having a grooved pattern, matching the grooved pattern of the added thermoplastic material plate.

[0009] The invention will be better understood from the following description, which relates to preferred embodiments, given by way of non-limiting examples, and explained with reference to the accompanying schematic drawings, in which:

[0010] [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;

[0011] [Fig. 2] is a cross-sectional view of the module shown in figure 1;

[0012] [Fig. 3] is a perspective view illustrating the implementation of the thermal regulation circuit on the first constituent part of the protection box shown in figures 1 and 2;

[0013] [Fig. 4] is a top perspective view of an electronic power and / or electrical energy storage module comprising a protective housing according to a second embodiment of the invention;

[0014] [Fig. 5] is another perspective view of the module shown in figure 4, with the two constituent parts of the protective housing separated;

[0015] [Fig. 6] is a cross-sectional view of the module shown in figure 4;

[0016] [Fig. 7A], [Fig. 7B] and [Fig. 7C] illustrate three successive stages of the process of making the thermal regulation circuit on areas of external surfaces of the first constituent part of the protective housing shown in figures 4 to 6;

[0017] [Fig. 8] is a perspective view of the outer face of the first constituent part of a protective housing according to a third embodiment of the invention, provided with a thermal regulation circuit;

[0018] [Fig. 9] is a perspective view of the outer face of the first constituent part of a protective housing according to a fourth embodiment of the invention, provided with two independent thermal regulation circuits;

[0019] [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;

[0020] [Fig. 1 1 ] is a perspective view of the outer face of the first constituent part of the protective housing of figure 1, further comprising a network (16) of interconnected reinforcing ribs and / or stiffening wings.

[0021] Figures 1 to 6 in particular illustrate a protective housing (1), especially 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 a second part (3') assembled at the level of respective peripheral wings (3”) forming a joining plane (PJ), the first (3) at least of said parts (3, 3') being made of a metallic body (4) comprising at least one external surface area (4', 4”, 4'”) at least one liquid thermal regulation circuit (5, 5', 5”).

[0022] According to the invention, it is provided that the or each thermal regulation circuit (5, 5', 5") is formed by an attached plate (6) made of thermoplastic material, that this plate (6) has a grooved pattern (7, 7', 7”, 7'”) defining the grooves of the channel or channels of circulation of the or each circuit (5, 5', 5”) and that this plate (6) is indirectly joined to said metal body (4) by a weld connection with an intermediate discontinuous or perforated thermoplastic layer (8), overmolded on the relevant outer surface area (4', 4”, 4'”) and having a grooved pattern (9, 9', 9”, 9'”) matching the grooved pattern (7, T , 7”, 7'”) of the attached thermoplastic material plate (6).

[0023] The circulation channel or each circulation channel of the liquid thermal regulation circuit or circuits (5, 5', 5") is thus formed by mutual cooperation i) of the grooves of the grooved pattern (7, T, 7", 7'") of the added thermoplastic material plate (6), ii) of the coincident grooves (absence of molded material) of the grooved pattern (9, 9', 9", 9'") of the discontinuous intermediate thermoplastic layer (8) and iii) of the relevant outer surface area (4', 4", 4'") of the constituent part (3) of the housing (1).

[0024] The implementation of a bonding interface (the discontinuous or perforated intermediate thermoplastic layer (8), which also contributes to the creation of the channels or conduits for the circulation of the heat transfer fluid, makes it possible to guarantee A watertight and resistant bond is established, firstly, with the relevant outer surface of the component part (3) of the housing (1) – the layer (8) being locally overmolded like a bead capable of following a 3D surface geometry and possibly consisting of a material specifically adapted to this function – and, secondly, with the thermoplastic plate (6), for which it acts as a bonding primer, made of a thermoplastic material compatible for 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.

[0025] In addition to the coincident thermoplastic material strips, defining the grooved patterns of the layer (8) and the plate (6) and assembled together to form the channels of the or each circuit (5, 5', 5") of liquid thermal regulation, the layer (8) and the plate (6) also each include, on their periphery, a continuous thermoplastic material strip whose mutual assembly provides a peripheral seal to the corresponding circuit (5, 5', 5").

[0026] The implementation, for the realization of the thermal regulation circuit or each circuit, of a plate (6) made of thermoplastic material, which in any case has a lower thermal conductivity than the metal forming the body (4), makes it possible to promote the heat exchange between the thermal regulation fluid and the inside of the housing (1) with respect to the external environment, or even to isolate the thermal regulation circuit(s) (5, 5', 5") from the external environment when said thermoplastic material has specific thermal insulation properties.

[0027] 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 for this purpose.

[0028] Advantageously, and as illustrated by example in the attached figures, the first constituent part (3) corresponds to a casing in the form of hollow shell or having several hollow shapes, defining part or even the majority of the internal volume of the case (1) and intended to receive the power electronic components (2') and / or the electrical energy storage elements (2"), or similar electrical / electronic functional elements.

[0029] In accordance with an important feature of the invention, the attachment zones (10) of the discontinuous intermediate thermoplastic layer (8) at the level of the relevant external surface zone(s) (4', 4”, 4'”) of the metal body (4) have a surface condition that promotes the bonding by mechanical attachment and / or by chemical adhesion of said intermediate thermoplastic layer (8) with the metal body (4).

[0030] The surface condition promoting the adhesion or bonding of the overmolded thermoplastic material to the external surface(s) (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 a chemical treatment such as passivation, phosphatization, plasma treatment or anodizing.

[0031] The or each external surface (4', 4”, 4'”) may advantageously have a flat or slightly curved shape, or at least a shape allowing the implementation of a surface treatment of the aforementioned type and the watertight bonding of the intermediate, discontinuous or perforated, overmolded thermoplastic layer (8).

[0032] Preferably, the thermoplastic material of the plate (6) and that of the discontinuous intermediate layer (8) are chemically compatible, preferably identical, and both advantageously consist of a material chosen from thermoplastic materials, possibly incorporating reinforcing fillers of the fibre or similar type, such as polypropylene or a material from the polyamide or polyketone family.

[0033] In accordance with a first 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 external surface area (4') by superimposed cooperation of a plate (6) of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said flat external surface area (4'), this external surface area (4') corresponding to the bottom of an internal region (3'”) recessed or in depression, in particular in relation 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).

[0034] In accordance with a second embodiment of the invention, illustrated for example in Figure 8, the housing (1) comprises a single thermal regulation circuit (5) arranged on at least two contiguous external surface areas (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 areas (4' and 4'”), one (4') of these external surface areas (4') corresponding to the bottom of an internal region (3'”) recessed or in depression, 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).

[0035] According to a third embodiment of the invention, illustrated for example in Figure 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) of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said external surface area (4') or said external surface areas (4', 4", 4'") concerned.

[0036] In accordance with a fourth 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") fluidically connected to each other, these thermal regulation circuits (5, 5', 5") being arranged on the same external surface area (4') or on at least two different external 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 external surface area (4') or said external surface areas (4', 4", 4'") concerned.

[0037] In the context of the third and fourth variants mentioned above, it may be provided that said at least two different external surface areas (4', 4") are located in planes parallel to the jointing plane (PJ), but offset from the latter and possibly from each other, and each correspond to the bottom of an internal region (3'") recessed or in depression, 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 casing (1).

[0038] In the context of the second, third and fourth variants mentioned above, it may be provided that said at least two different external surface areas (4', 4") located in planes parallel to the jointing plane (PJ) are connected to each other by an intermediate surface area (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) of thermoplastic material and the intermediate discontinuous or perforated thermoplastic layer (8) concerned with said inclined external surface area (4'").

[0039] In order to avoid any need to specifically create fixing or positioning sites in any of the constituent parts (3, 3'), particularly in the first part (3), for example in the context of time-consuming additional operations, the housing (1) may include at least one, preferably several, part(s) (11, 11') for positioning and / or fixing power electronic 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 bonded adhesively or by metal / thermoplastic welding to the inner face of the metal body (4) of the first constituent part (3).

[0040] Advantageously, and as shown for example in Figures 2, 5 and 7A, the positioning and / or fixing parts (11, 11') comprise screw bushings (11) or similar support and fixing studs, attached by adhesive bonding or metal / thermoplastic welding to the inner face of the relevant part (4, 4') of the housing (2), or overmolded onto this face. Some of these bushings 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).

[0041] Alternatively or additionally, it may be provided that the positioning and / or fixing parts (1 1 , 1 1') include at least one mounting plate (1 1') with feet, bonded by adhesive or by metal / thermoplastic welding to the inner face of the part (4, 4') of the housing (2) concerned, or formed by overmolding on this face.

[0042] The metal / thermoplastic welding for joining the parts (1 1 , 1 1 ') can for example be carried out by implementing the process described in document US11745295.

[0043] The power electronic components (2') and / or electrical energy storage elements (2"), or similar electrical / electronic functional elements, are mounted on the portion (4, 4') of the housing (2) such that they are in direct contact with the inner face of the wall of the portion (4, 4') of the housing (2) on which they are mounted, said portion having a hollow shape adapted to accommodate them in cooperation with the other constituent part of the housing. A thermal regulation circuit (5, 5', 5") may advantageously be provided on the opposite outer face of this wall.

[0044] In relation to the practical implementation on site of the module (2) and its connection, the housing (1) advantageously includes, and preferably at the level of the first constituent part (3), at least one passage opening (12) for the electrical connection of the power electronic components (2') and / or the electrical energy storage elements (2"), or similar electrical / electronic functional elements, intended to be housed in said housing (1), with the outside.

[0045] As shown in Figures 2, 5 and 6, and still in relation to the connection of the module (2) at its installation site, the housing (1) can include either, mounted on one side of the passage opening (12), a passage-forming means defining a passageway between the inside of the housing (1) and the outside, or, arranged on either side of the passage opening (12), complementary passage-forming means (13 and 13') ensuring, through mutual cooperation, the creation of a passageway between the inside of the housing (1) and the outside, the or each means of passage (13, 13') being possibly secured to the housing (2) by at least one positioning and / or fixing part (1 1 , 1 1 '), respectively on the inner and / or outer face(s) of the first constituent part (3).

[0046] The configuration and arrangement of the means of forming a passage or of the construction resulting from the cooperation of the means (13, 13') of forming a passage through the opening (12), advantageously allows the electromagnetic shielding properties of the housing (1) to remain intact, when this is required.

[0047] 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 optionally one or more hollow shape(s) defining at least part of the internal volume of said casing (1), and the second constituent part (3') forming casing cover, advantageously consists of a formed sheet, or a cast or welded metal part, preferably made of aluminum or a metal alloy, the joining plane (PJ) formed by cooperating and coincident peripheral wings (3”) of the constituent parts (3 and 3') incorporating a sealing gasket, where appropriate suitable for preserving electromagnetic protection.

[0048] When the weight and cost of the metal body (4) of the first constituent part (3) must be reduced, and may then result in a thickness insufficient to give sufficient rigidity to the housing (1), it may be provided, as shown in Figure 11 by way of example, that at least the first constituent part (3) comprises a metal body (4) consisting of a thin sheet formed, 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.

[0049] The pipettes (15, 15) for supplying and draining the liquid from the thermal control circuit(s) (5, 5', 5") can either be formed as a single piece with the plate (6), or attached to this plate (by welding or by a means of fixing with the implementation of a joint), or they can be formed with the perforated intermediate layer (8). In terms of shapes, they can each be straight or angled, indifferently to each other and depending, for example, on the possibilities of connecting each.

[0050] Screwing barrels (17) can also be formed by overmolding at the peripheral wings (3”) of the first constituent part (3) for screw assembly of the two parts of the housing (1), if necessary at the same time as the perforated layer (8).

[0051] The invention also relates (figures 1, 2 and 4 to 6) to a power electronic and / or electrical energy storage module (2), comprising a protective housing (1) in which are mounted power electronic components (2') and / or electrical energy storage elements (2”), or similar electrical / electronic functional elements.

[0052] 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 power electronic components (2') and / or the electrical energy storage elements (2"), or the similar electrical / electronic functional elements, are mounted in said housing (1) in contact with a portion of the housing wall (1) corresponding to an external surface area (4', 4", 4'") of the latter comprising at least one liquid thermal regulation circuit (5, 5', 5").

[0053] 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.

[0054] 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 are mounted power electronic components (2') and / or electrical energy storage elements (2"), or similar electrical / electronic functional elements, said protective housing (1) advantageously being a protective housing as described above.

[0055] This method is characterized in that it consists of providing a first constituent part (3) consisting of a metallic body (4) forming a housing and comprising at least one external surface area (4', 4”, 4'”) at least one liquid thermal regulation circuit (5, 5', 5”), mounting the power electronic components (2') and / or the electrical energy storage elements (2”), or the similar electrical / electronic functional elements, in said metallic body (4) forming a housing and assembling a second metallic constituent part (3') forming a cover with said first constituent part (3) by means of mutually coincident respective peripheral wings (3”), forming by cooperation a jointing plane (PJ), preferably with interposition of a sealing gasket, so as to obtain a module (2) with a protective housing (1) advantageously forming a Faraday cage or shield and preferably sealed.

[0056] In accordance with an important feature of the invention, and as more specifically shown in Figures 3 and 7, the thermal regulation circuit(s) (5, 5', 5") is achieved by indirectly bonding a thermoplastic plate (6), which has a grooved pattern (7, T, 7", 7'") defining the grooves of the circulation channel(s) of each circuit(s) (5, 5', 5"), to the relevant outer surface area(s) (4', 4", 4'"), by means of a discontinuous or perforated intermediate thermoplastic layer (8), previously overmolded onto the relevant outer surface area (4', 4", 4'"), having a grooved pattern (9, 9', 9", 9'") that coincides with that of the added thermoplastic plate (6) and to which said thermoplastic plate (6) is bonded by coincidental overlap welding. of their respective grooved patterns.

[0057] According to a preferred embodiment of the invention, also shown in Figures 3 and 7, the implementation of the thermal regulation circuit(s) (5, 5', 5") comprises the steps of overmolding onto the relevant outer surface area (4', 4", 4'") a discontinuous or perforated thermoplastic layer (8), providing a grooved pattern (9, 9', 9", 9'") which coincides with that of the circulation channel(s) of the circuit(s) (5, 5', 5"), and then attaching onto this overmolded thermoplastic layer (8) a plate (6) of thermoplastic material which has a grooved pattern (7, T, 7", 7'") defining the grooves of the channel or channels of circulation of the or each circuit (5, 5', 5"), by positioning said plate (6) in a superimposed manner with respect to said layer (8) and with coincidence of their respective grooved patterns, and to secure said plate (6) with said layer (8) by welding.

[0058] Advantageously, the manufacturing process may consist of carrying out, before overmolding the discontinuous intermediate thermoplastic layer(s) (8), at least at the attachment zones (10) of this or these intermediate thermoplastic layer(s) (8) on the relevant external surface zone(s) (4', 4”, 4”') of the metal body (4), a preliminary preparation operation of the aforementioned zone(s) (4', 4”, 4”') to obtain a surface finish that promotes bonding by mechanical attachment or chemical adhesion of said intermediate thermoplastic layer (8) to the metal body (4). For this purpose, one of the treatments indicated above may be used.

[0059] Preferably, the manufacturing process may also consist, before mounting the power electronic components (2') and / or the electrical energy storage elements (2"), or the similar electrical / electronic functional elements, in the metal body (4) forming the housing, of producing one or more positioning and / or fixing parts (11, 11') made of thermoplastic material, overmolded or attached and bonded by adhesive or metal / thermoplastic welding with the inner face of the metal body (4) of the first constituent part (3).

[0060] The part(s) (11, 11') for positioning and / or fixing power electronic components (2') and / or electrical energy storage elements (2"), may optionally be overmolded on the inner face of the metal body (4) simultaneously with the layer (8) on the outer face of this body (4).

[0061] Finally, and particularly when the metal body (4) of the first part is thin, the manufacturing process may also consist, before, after, or during the overmolding of the relevant outer surface area (4', 4”, 4'”) of the metal body (4) with the discontinuous or perforated layer (8) of thermoplastic material, providing the grooved pattern (9, 9', 9”, 9'”), of overmolding at least the outer face of said metallic body (4), advantageously each of the outer and inner faces of this body (4), of 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.

[0062] A possible practical variant of a two-step process for making at least one liquid thermal regulation circuit (5, 5', 5") on the outer face of the metal body (4) forming the housing of the first constituent part (3) will be described in more detail below (see also figures 7A to 7C).

[0063] In a first step, a thermoplastic overmolding of a perforated layer or an intermediate bead (8) is carried out on the metal housing (4): mechanical adhesion forms a mechanical bond and a seal between the metal and the thermoplastic. This improved mechanical bond or adhesion is ensured by local or global mechanical preparation of the surfaces of the metal housing (4) and / or by preparation in chemical baths, for example anodizing, or one of the other types of surface treatments mentioned herein.

[0064] The metal casing (4) can be placed in a suitable overmolding mold either at room temperature or preheated to a temperature below the melting point of the thermoplastic.

[0065] The thermoplastic is injected onto the metal casing in the mold to form the bead or the intermediate perforated layer (8) by making a deposition according to a negative pattern with respect to the pattern of the circuit(s) (5, 5', 5") of thermal regulation and using an amount of energy proportional to the amount of thermoplastic mass used (therefore limited).

[0066] The closing of the injection mold on the metal casing (4) allows for the management of flatness defects, and ensures a more precise geometry of said intermediate bead (8).

[0067] The second step of the process consists of welding the thermoplastic material plate (6) onto the intermediate thermoplastic bead or perforated layer (8), using one of the various known welding processes, with a possible tolerance on the process settings.

[0068] Thanks to the prior overmolding of the injected cord or intermediate layer (8), the shapes can conform to the 3D relief of the metal casing (4), as shown in particular in figures 7A, 8 and 10.

[0069] Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications remain possible, particularly with regard to the composition of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

Claims

1. A protective housing (1), particularly for a power electronic and / or electrical energy storage module (2), comprising at least two constituent parts (3, 3') peripherally assembled together, namely advantageously a first part (3) and at least a second part (3') assembled at the level of respective peripheral flanges (3”) forming a joining plane (PJ), the first (3) at least of said parts (3, 3') being made of a metallic body (4) having at least one external surface area (4', 4”, 4'”) at least one liquid thermal regulation circuit (5, 5', 5”), a protective housing (1) characterized in that said or each thermal regulation circuit (5, 5', 5”) is formed by an attached plate (6) made of thermoplastic material, in that this plate (6) has a grooved pattern (7, 7', 7”) 7'") defining the gorges of the channel or circulation channels of the or each circuit (5, 5',5”) and in that this plate (6) is indirectly joined to said metal body (4) by a welded connection with a discontinuous or perforated intermediate thermoplastic layer (8), overmolded onto the relevant outer surface area (4', 4”, 4'”) and having a grooved pattern (9, 9', 9”, 9'”) matching the grooved pattern (7, T, 7”, 7'”) of the added thermoplastic plate (6).

2. Protective housing (1) according to claim 1, characterized in that the fixing zones (10) of the discontinuous intermediate thermoplastic layer (8) at the level of the relevant external surface zone(s) (4', 4”, 4'”) of the metal body (4) have a surface condition promoting the bonding by mechanical attachment and / or by chemical adhesion of said intermediate thermoplastic layer (8) with the metal body (4). [Claims] Protective housing (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 chemically compatible, preferably identical, and both advantageously consist of a material selected from thermoplastic materials, optionally incorporating reinforcing fillers such as fibers or analogous materials, such as polypropylene or a material from the polyamide or polyketone family.

4. Protective housing (1) according to any one of claims 1 to 3, characterized in that it comprises a single thermal regulation circuit (5) formed on an external surface area (4') by superimposed cooperation of a plate (6) of thermoplastic material and an intermediate thermoplastic layer (8) discontinuous or perforated with said external surface area (4') which is flat, and in that this external surface area (4') corresponds to the bottom of an internal region (3'”) recessed or in depression, in particular with respect to the jointing plane (PJ), of the metal body (4'), the latter forming a hollow and open housing, defining the major part of the internal volume of said housing (1). [Claims] 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 areas (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 areas (4' and 4'”), and in that one (4') of these external surface areas (4') corresponds to the bottom of an internal region (3'”) recessed or in depression, 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). [Claims] Protective housing (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) 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 circuits (5, 5', 5") of separate thermal regulation circuits fluidly connected to each other, these thermal regulation circuits (5, 5', 5") being arranged on the same external surface area (4') or on at least two different external 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 external surface area (4') or said external surface areas (4', 4”, 4'”) concerned. [Claims] Protective housing (1) according to any one of claims 6 and 7, characterized in that said at least two different external surface areas (4', 4") are located in planes parallel to the jointing plane (PJ), but offset from the latter and possibly from each other, and each correspond to the bottom of an internal region (3'") recessed or in depression, in particular with respect to the jointing plane (PJ), of the metal body (4'), the latter forming a hollow and open housing, defining the major part of the internal volume of said housing (1).

9. Protective housing (1) according to any one of claims 6 to 8, characterized in that said at least two different external surface areas (4', 4") located in planes parallel to the jointing plane (PJ) are connected to each other by an intermediate surface area (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 thermoplastic material plate (6) and the relevant discontinuous or perforated intermediate thermoplastic layer (8) with said inclined external surface area (4'").

10. A 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 power electronic components (2') and / or electrical energy storage elements (2"), the part(s) (11, 11') being made of a thermoplastic material and joined by adhesive or welding metal / thermoplastic with an inner face of the metallic body (4) of the first constituent part (3). [Claim 1 1] Protective housing (1 ) according to claim 10, characterized in that the positioning and / or fixing parts (1 1 , 1 1 ') comprise screw barrels (1 1 ) or support and fixing studs, attached by adhesive bonding or by metal / thermoplastic welding to the inner face of the metal body (4) of the constituent part (3) of the housing (2) concerned, or overmolded onto 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, bonded by adhesive or by metal / thermoplastic welding to 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 power electronic components (2') and / or the electrical energy storage elements (2"), intended to be housed in said housing (1), with the outside.

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 inside of the housing (1) and the outside, 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 inside of the housing (1) and the outside, the 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 inner and / or outer 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 aluminium or a metal alloy, forming an open casing, with possibly one or more hollow shape(s) defining at least part of the internal volume of said casing (1), and in that the second constituent part (3') forming casing cover, advantageously consists of a formed sheet, or a cast or welded metal part, preferably made of aluminium 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 sealing gasket, where appropriate suitable for 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 metal body (4) consisting of a thin sheet formed, 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 said body (4), a network (16) of interconnected reinforcing ribs and / or stiffening wings.

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

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

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

20. A manufacturing method according to claim 19, characterized in that the thermal regulation circuit or circuits (5, 5', 5") is formed by indirectly bonding a thermoplastic plate (6), which has a grooved pattern (7, T, 7", 7'") defining the grooves of the circulation channel or channels of the circuit or circuits (5, 5', 5"), with the relevant outer surface area(s) (4', 4", 4'"), by means of a discontinuous or perforated intermediate thermoplastic layer (8), previously overmolded onto the relevant outer surface area (4', 4", 4'"), having a grooved pattern (9, 9', 9", 9'") which coincides with that of the attached thermoplastic plate (6) and with which said plate (6) made of thermoplastic material is joined by welding with coincidental superposition of their respective grooved patterns.

21. A manufacturing method according to claim 19 or 20, characterized in that the production of the thermal regulation circuit(s) (5, 5', 5") comprises the steps of overmolding onto the relevant outer surface area (4', 4", 4") a discontinuous or perforated thermoplastic layer (8), providing a grooved pattern (9, 9', 9", 9") which coincides with that of the circulation channel(s) of the circuit(s) (5, 5', 5"), and then attaching onto this overmolded thermoplastic layer (8) a plate (6) of thermoplastic material which has a grooved pattern (7, 7", 7") defining the grooves of the circulation channel(s) of the circuit(s) (5, 5', 5"), by positioning said plate (6) in a superimposed manner with respect to said layer (8) and with coincidence of their grooved patterns respective, and to join said plate (6) with said layer (8) by welding.

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

23. A manufacturing method according to any one of claims 19 to 22, characterized in that it consists, before the assembly of the power electronic components (2') and / or the electrical energy storage elements (2"), in the metal body (4) forming the housing, of making one or more positioning and / or fixing parts (11, 11') in thermoplastic material, overmolded or attached and bonded by adhesive or by metal / thermoplastic welding with the inner face of the metal body (4) of the first constituent part (3).

24. A manufacturing method according to any one of claims 21 and 22, characterized in that it consists, before, after, or during the overmolding of the relevant outer surface area (4', 4”, 4'”) of the metal body (4) with the discontinuous or perforated layer (8) of thermoplastic material, providing the grooved pattern (9, 9', 9”, 9'”), of overmolding at least the outer face of said metal body (4), advantageously each of the outer and inner faces of said 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 relevant outer surface area (4', 4”, 4'”), j

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