Supply module, supply system, and associated vehicle and assembly method

Abstract

The present invention relates to an electric supply module (20) comprising a power generation unit (22), comprising a first casing (34), and a power conversion unit (36), comprising: - input terminals (38), - output terminals (44), connected to an output of an electrical converter (40b); and - a second casing (46), the power generation unit (22) being stacked on the power conversion unit (36). The supply module (20) further comprises a seal (56) interposed between an upper face of the second casing (46) and a lower face of the first casing (34) and the connection between the output connectors (30) and the input terminals (38) is made in an interior module space (V20), formed from an internal volume (V34) of the first casing (34), from an internal volume (V46) of the second casing (46) and from a connection space (V56).

Description

[0001] TITLE: Power supply module, power supply system, vehicle and associated assembly process

[0002] The present invention relates to a power supply module, as well as an associated power supply system, vehicle and assembly method.

[0003] It is known to use a power module comprising a fuel cell and an electrical converter to adapt the voltage of the electrical current supplied by the fuel cell, for example, to a power battery used to power an electric motor. This is achieved by electrically connecting the fuel cell and the converter, for example, via cables or busbars.

[0004] US10243231 B2 describes a fuel cell system comprising a fuel cell portion and a high-voltage circuit portion, fixed together. In particular, the high-voltage circuit portion may be fixed below the fuel cell portion.

[0005] However, optimizing the electrical connection between the fuel cell and the converter remains necessary to minimize the size of the power supply module. Furthermore, current solutions for connecting the fuel cell and converter often use electrical cables located outside the enclosures containing the fuel cell or converter, requiring costly electrical insulation and resulting in a significant increase in size. Moreover, such a system is complex to assemble and risky to handle if the cable insulation is damaged.

[0006] The aim of the invention is therefore to offer a power supply module allowing a secure electrical connection and limited size.

[0007] To this end, the invention relates to a power supply module comprising: a power generation unit, comprising: o a fuel cell, including current-collecting electrodes; o output connectors, each current-collecting electrode being respectively electrically connected to one of the output connectors; o a first enclosure, the fuel cell being disposed in the first enclosure, a power conversion unit, comprising: o input terminals, each input terminal being respectively connected to one of the output connectors in order to be electrically supplied; o an electrical converter having one input connected to the input terminals in order to be electrically supplied via the input terminals; o a power switch, connected to the electrical converter, configured to interrupt or allow the flow of an electrical current circulating in the converter;o output terminals, connected to an output of the electrical converter and configured to be connected to an electric traction motor of the vehicle in order to electrically power the electric traction motor, o a second enclosure, the converter and the power switch being arranged in the second enclosure, the power generation unit being stacked on top of the power conversion unit in a height direction, the power generation and conversion units being fixed to each other.;

[0008] According to the invention, the power supply module further comprises a seal forming a closed loop, interposed between an upper face of the second envelope and a lower face of the first envelope along the height direction, the seal and the upper and lower faces delimiting a connection space.

[0009] Also according to the invention, the connection between the output connectors and the input terminals is made in an internal module space, formed of an internal volume of the first envelope, an internal volume of the second envelope and the connection space.

[0010] Thanks to this invention, the power supply module's footprint is reduced. Positioning the power generation unit and the power conversion unit in direct contact with each other, and ensuring that the connection between the output connectors and input terminals is located within the module's internal space, eliminates the need for external connections, such as cables, and also limits their length. For example, the output connectors and input terminals can be in direct contact with each other, or connected via a means that is entirely contained within the module's interior. Furthermore, the gasket ensures that the power generation unit and the power conversion unit are sealed against external elements, such as dust or water, thus guaranteeing a secure electrical connection that will not deteriorate over time.Stacking the power generation unit on top of the power conversion unit also limits, if not eliminates, any risk of hydrogen accumulating in the power conversion unit, thus reducing the risk of fire or explosion. Because hydrogen is lighter than air, it will not accumulate in or around the power conversion unit, even though the power generation unit and the power conversion unit are fixed and potentially connected.

[0011] Furthermore, the fact that the power conversion unit is located below the power generation unit allows for easier connection to other vehicle components, particularly the battery and / or motor, when the system comprising the invention is arranged on the roof of the vehicle, as is the case for buses in particular.

[0012] According to other advantageous aspects of the invention, the module comprises one or more of the following features, taken individually or in all technically possible combinations:

[0013] - the output connectors and input terminals are spaced apart and electrically connected by an intermediate connection device, located entirely within the module's interior space;

[0014] - the module includes an opening, passing through the lower face of the first envelope and the upper face of the second envelope, at the level of the connection space, and in which the output connectors and the input terminals are opposite the opening in the direction of height and electrically connected through the opening;

[0015] - a height of the power conversion unit, measured from the top face in a direction opposite to the height direction, is less than a height of the power generation unit, measured from the bottom face in the height direction, preferably less than two-thirds of the height of the power generation unit, preferably less than or equal to half the height of the power generation unit;

[0016] - a length of the power generation unit, measured along a length direction, perpendicular to the height direction, is equal to a length of the power conversion unit, measured along the length direction;

[0017] - a width of the power generation unit, measured along a width direction, perpendicular to the height and length directions, is equal to a width of the power conversion unit, measured along the width direction;

[0018] - The power conversion unit includes a coolant inlet and a coolant outlet to cool the internal volume of the power conversion unit. The invention also relates to a power supply system comprising a power module as described above, the coolant being air, and further comprising an air circuit configured to circulate air into the fuel cell, the air circuit comprising an air inlet and an auxiliary air supply line fluidly connected downstream of the air inlet and fluidly connected to the coolant inlet.

[0019] According to other advantageous aspects of the invention, the supply system further comprises a compressor fluidly connected to, and downstream of, the air inlet, the auxiliary air intake line being connected downstream of the compressor;

[0020] The invention also relates to a power supply system comprising a power supply module as described above, the cooling fluid being a coolant, and further comprising a cooling circuit, comprising an auxiliary cooling circuit including an auxiliary coolant intake line fluidly connected to the coolant intake.

[0021] According to other advantageous aspects of the invention, the power supply system further includes a heat exchanger connected to the auxiliary cooling outlet line and to an air circuit supplying the fuel cell.

[0022] The invention also relates to a vehicle comprising: a system as described above; an electric traction motor for the vehicle, supplied with electric current by the power module via the output terminals, and in which, when the vehicle is placed on a ground surface, the height direction is perpendicular to the ground surface and directed away from the ground surface.

[0023] According to other advantageous aspects of the invention, the vehicle further comprises a battery, electrically connected to the output terminals by a battery connection device, and electrically connected to the electric traction motor, so that the electric traction motor is powered by the power module via the output terminals, through the battery.

[0024] The invention also relates to a method of assembling a power supply module as described above, the method comprising the following steps: positioning the gasket on one face between the lower face of the first enclosure and on the upper face of the second enclosure; aligning and bringing together the lower face of the first enclosure and the upper face of the second enclosure; connecting the output connectors to the input terminals in the connection space; bringing the gasket into contact with another face between the lower face of the first enclosure and the upper face of the second enclosure; and fixing the power generation unit and the conversion unit.

[0025] According to other advantageous aspects of the invention, the joint arrangement step comprises the arrangement of the joint on the lower face of the first envelope, the method further comprising: a preliminary step of positioning the first envelope, such that the lower face is arranged above an upper face of the first envelope, the upper face being parallel to the lower face; and the step of fixing the power generation unit and the conversion unit having been carried out, a step of turning the module over, such that the power generation unit is arranged on the power conversion unit.

[0026] The invention will become clearer upon reading the following description, given solely by way of non-limiting example, and made with reference to the drawings in which:

[0027] [Fig. 1] Figure 1 is a diagram of a vehicle according to the invention;

[0028] [Fig. 2] Figure 2 is a diagram of a power supply system according to the invention;

[0029] [Fig. 3] Figure 3 is an exploded view of a power supply module according to the invention;

[0030] [Fig. 4] Figure 4 is a perspective view of a power conversion unit according to the invention;

[0031] [Fig. 5] Figure 5 is a cross-section of the generation module along plane IV;

[0032] [Fig. 6] Figure 6 is a flowchart of an assembly method according to the invention; and

[0033] [Fig. 7] Figure 7 is a diagram of a power supply system according to another embodiment of the invention.

[0034] Figure 1 represents a vehicle 1 comprising a power system 10, a motor 12, and advantageously, a battery 14, electrically connected to the motor 12. The vehicle 1 is, for example, a truck, as shown in Figure 1. Alternatively, the vehicle 1 is a bus, or a car.

[0035] Vehicle 1 is configured to move on a surface of area S. Advantageously, the surface S is substantially horizontal, meaning that it can, for example, follow the different variations in horizontality of a road. A vertical direction V is then defined as perpendicular to the surface of the ground S, and extending in the opposite direction to the surface of the ground S.

[0036] Motor 12 is an electric traction motor for vehicle 1. In particular, motor 12 is configured so that vehicle 1 moves when motor 12 is in operation.

[0037] The power supply system 10 is shown in more detail in Figure 2 and includes a power supply module 20, also referred to simply as the module. The power supply module 20 includes a power generation unit 22. The power generation unit 22 includes a fuel cell 24. The fuel cell 24 includes at least one stack 26 of electrochemical cells, as shown in Figure 2. The electrochemical cells of a fuel cell are known per se and are not described in further detail.

[0038] The fuel cell 24 also includes current-collecting electrodes 28, also called current-collecting plates or simply electrodes, electrically connected to output connectors 30. In the example in Figure 2, the fuel cell 24 includes two current-collecting electrodes 28. The electrodes 28 are arranged on either side of the stack 26, each electrode 28 being in contact with the electrochemical cell at one end of the stack 26. In particular, one of the electrodes 28 constitutes a positive electrode, and the other electrode 28 constitutes a negative electrode.

[0039] Each current-collecting electrode 28 is electrically connected to one of the output connectors 30. The connection between the electrodes 28 and the output connectors 30 is made, for example, by cables 32, or, alternatively, by sets of metal busbars. Advantageously, the output connector 30 connected to the positive electrode 28 is called the positive output connector, and the output connector 30 connected to the negative electrode 28 is called the negative output connector. In other words, the output connectors 30 comprise a positive output connector and a negative output connector.

[0040] In an alternative not shown, the fuel cell 24 comprises several stacks 26 of electrochemical cells, with electrodes 28 arranged on either side of each stack 26. The positive electrodes 28 are all connected to the same output connector 30, which is then the positive output connector, and the negative electrodes 28 are all connected to the other output connector 30, which is then the negative output connector.

[0041] The power generation unit 22 also includes a first casing 34, visible in Figure 2 and shown in detail in Figure 3. The term "casing," or housing, or enclosure, is advantageously used to designate any shape delimiting an internal space, or cavity, intended to house various components, in this case, in particular the fuel cell 24. The casing 34 is, for example, substantially parallelepiped in shape. The casing 34 is, for example, made of metallic material, in particular aluminum or cast aluminum.

[0042] The fuel cell 26 is arranged in the casing 34. In other words, the casing 34 forms an internal volume V34, in which the fuel cell 26 is arranged.

[0043] Advantageously, the cables 32 are also entirely arranged within the enclosure 34, i.e., within the internal volume V34. This protects the cables from the external environment (water, dust, etc.) and facilitates the handling of the power generation unit 22.

[0044] In the example shown in Figure 2, the output connectors 30 are also arranged within the enclosure 34. This protects them from the external environment (water, dust, etc.). In an alternative configuration not shown, the output connectors 30 are located outside the enclosure 34, for example, protruding from the enclosure 34.

[0045] The casing 34 includes a lower face 34a, which extends along a plane defined by directions of length X and width Y, perpendicular to each other and perpendicular to a direction of height Z. The direction of height Z is parallel to the vertical direction V and oriented in the same direction as the vertical direction V when the power supply module 20 is located in the vehicle 1, and the vehicle 1 rests on the horizontal or substantially horizontal ground surface S. In other words, when the power supply module 20 is located in the vehicle 1, and the vehicle 1 rests on the horizontal or substantially horizontal ground surface S, the direction of height Z is perpendicular to the ground surface S and oriented in the opposite direction to the ground surface S.

[0046] The envelope 34 advantageously includes an upper face 34b, which extends parallel to the lower face 34a and opposite the lower face 34a along the height direction Z.

[0047] Advantageously, the power generation unit 22 has a height Z22, measured along the Z-height direction from the lower face 34a and advantageously to the upper face 34b. Alternatively, if the lower face 34a and upper face 34b are irregular along the Z-height direction, then the height Z22 is advantageously the maximum distance between the lower face 34a and upper face 34b measured along the Z-height direction. For example, the height Z22 of the power generation unit 22 is between 100 mm and 500 mm, preferably between 250 mm and 350 mm, advantageously on the order of 280 mm. Advantageously, the power generation unit 22 also has a length X22, measured along the length direction X. For example, the length X22 of the power generation unit 22 is between 200 mm and 1000 mm, preferably between 400 mm and 700 mm, advantageously in the order of 540 mm.

[0048] Advantageously, the power generation unit 22 also has a width Y22, measured along the width Y direction. The length X22 is, for example, greater than or equal to the width Y22. For example, the width Y22 of the power generation unit 22 is between 200 mm and 700 mm, preferably between 300 mm and 600 mm, advantageously around 470 mm. The module 20 further includes a power conversion unit 36, which comprises input terminals 38, a power converter 40, an input 40a of which is connected to the input terminals 38, a power switch 42 connected to the power converter 40, and output terminals 44 connected to an output 40b of the power converter 40.

[0049] The 40 power converter is advantageously a chopper, or DC / DC converter, in other words, configured to convert direct current into direct current of a different voltage. The 40 power converter is, for example, a buck-boost type switching power supply.

[0050] The power switch 42 is connected to the power converter 40. Advantageously, the power switch 42 is connected to the input 40a of the power converter 40. The power switch 42 is configured to interrupt or allow the flow of an electric current through the converter 40. Advantageously, the power conversion unit 36 ​​includes a control unit 49, configured to control the power switch 42 between an open state and a closed state. In particular, the control unit 49 is configured to control the power switch 42 in the switched or open state.

[0051] The input 40a of the electrical converter 40 is connected to the input terminals 38, in order to be electrically supplied via the input terminals 38, for example by cables 50 or, in an alternative not shown, via busbars.

[0052] The output 40b of the electrical converter 40 is connected to the output terminals 44, via cables 52, or alternatively, via busbars.

[0053] The power conversion unit 36 ​​also includes a second enclosure 46, which is, for example, substantially parallelepiped-shaped, as shown in Figure 3. The term "enclosure," or housing, or casing, advantageously refers to any shape delimiting an internal space, or cavity, intended to house various components. The enclosure 46 is advantageously made of a metallic material, in particular aluminum or cast aluminum. The enclosure 46 includes an upper face 46a, which extends parallel to a plane defined by the length X and width Y directions.

[0054] The envelope 46 advantageously includes a lower face 46b, which extends parallel to the upper face 46a and opposite the upper face 46a in a direction Z' opposite to the height direction Z.

[0055] Advantageously, the power conversion unit 36 ​​has a height Z36, measured along the Z' direction from the upper face 46a and advantageously to the lower face 46b. Alternatively, if the upper face 46a and lower face 46b are irregular along the Z' direction, then the height Z36 is advantageously the maximum distance between the upper face 46a and lower face 46b measured along the Z' direction.

[0056] Advantageously, the height Z36 of the power conversion unit 36 ​​is less than the height Z22 of the power generation unit 22, preferably less than two-thirds of the height Z22, preferably again, less than or equal to half of the height Z22.

[0057] Advantageously, the power conversion unit 36 ​​also has a length X36, measured along the length direction X.

[0058] Advantageously, the 36 power conversion unit also has a Y36 width, measured along the Y width direction.

[0059] Advantageously, the length X22 of the power generation unit 22 is equal to the length X36 of the power conversion unit 36. Alternatively or in addition, the width Y22 of the power generation unit 22 is equal to the width Y36 of the power conversion unit 36. By equal, we preferentially mean a relationship of equality to plus or minus 10%.

[0060] The power converter 40 and the power switch 42 are housed within the enclosure 46. In other words, the enclosure 46 comprises an internal volume V46, in which the power converter 40 and the power switch 42 are located. Thus, the power conversion unit 36 ​​forms a complete and compact assembly, combining and integrating two different components within a single enclosure 46, which facilitates the mounting of the power supply module 20, as will be detailed later.

[0061] Advantageously, cables 50 and 52 are also arranged in the enclosure 46, i.e. in the internal volume V46. This protects the cables from the external environment (water, dust, etc.) and facilitates the handling of the power conversion unit 36.

[0062] Advantageously, the input terminals 38 are also arranged in the enclosure 46, or, in an alternative not shown, protrude from the enclosure 46. The output terminals 44 have, for example, the form of high-voltage sockets, provided in the enclosure 46.

[0063] As shown in Figure 2, the power conversion unit 36 ​​advantageously includes a coolant inlet 48 and a coolant outlet 49, in order to cool the interior of the power conversion unit 36. Indeed, the electrical converter 40 and the power switch 42 are components which will generate heat during their operation and it is desirable to be able to dissipate this heat.

[0064] The power generation unit 22 and the power conversion unit 36 ​​are stacked one on top of the other along the Z-axis. More precisely, the power generation unit 22 is stacked on top of the power conversion unit 36 ​​along the Z-axis. In other words, the power generation unit 22 is above the power conversion unit 36 ​​along the Z-axis. This arrangement effectively prevents any hydrogen that might accidentally escape from the fuel cell 24 from entering the vicinity of the power conversion unit 36. Since hydrogen is lighter than air, it will not tend to sink, but rather remain at a higher elevation, along the vertical V-axis mentioned earlier.This is particularly important from a safety point of view because hydrogen must be kept away from electric arcs that could potentially emerge accidentally from the power conversion unit 36, in particular from the power switch 42.

[0065] The power generation and conversion units 22 and 36 are fixed to each other. Advantageously, it is the casings 34 and 46 that are fixed to each other. In particular, the lower face 34a is fixed to the upper face 46a, for example by screws, not shown, arranged around the perimeter of faces 34a and 46a.

[0066] The power supply module 20 further includes a seal 56, forming a closed loop. Preferably, the closed loop, and therefore the seal 56, is polygonal in shape, advantageously rectangular, as illustrated. The seal 56 is, for example, formed of a metallic core 57 forming a closed loop, covered with an elastomeric material 58, which is, for example, silicone. The seal 56 is airtight and watertight, and advantageously, is also watertight against hydrogen gas.

[0067] The gasket 56 is interposed between the upper face 46a of the casing 46 and the lower face 34a of the casing 34 along the height direction Z. The gasket 56 and the upper and lower faces 46a and 34a thus define a connection space V56. When the power generation and conversion units 22 and 36 are fixed to each other, the gasket 56 is compressed to seal the connection space V56 against the external environment.

[0068] The connection space V56, the interior of the enclosure 34, i.e. the internal volume V34, and the interior of the enclosure 46, i.e. the internal volume V46, together form an internal module space V20. In other words, the internal module space V20 forms an enclosed space, hermetically sealed from the external environment by various components, including: the enclosure 34, the enclosure 46 and the gasket 56.

[0069] Advantageously, module 20 includes an opening 60 that passes through the lower face 34a of the casing 34 and the upper face 46a of the casing 46, at the level of the connection space V56. Thus, the opening 60 passes through the connection space V56, that is, it opens onto the connection space V56 on both sides along the height direction Z. The seal 56 thus surrounds the opening 60. The connection space V56, the internal volume V34, and the internal volume V46 can then be in fluidic communication with each other. In particular, air can circulate freely between the connection space V56, the internal volume V34, and the internal volume V46.

[0070] As illustrated, the opening 60 is preferably polygonal in shape, for example rectangular. Its length, measured along the Y direction, is for example between 100 mm and 300 mm, and is advantageously around 175 mm. Its width, measured along the X direction, is for example between 40 mm and 200 mm, and is advantageously around 90 mm. It is then understood that the shape and dimensions of the seal 56 are consistent with the shape and dimensions of the opening 60. For example, the seal has the same geometric shape as the opening 60, in this case rectangular, and has dimensions that are very slightly larger, for example by a few millimeters to a few centimeters, so as to be able to rest on the lower face 34a of the casing 34 and the upper face 46a of the casing 46 and to be able to seal the opening 60.

[0071] According to the invention, the output connectors 30 and the input terminals 38 are arranged within the internal space of module V20. This allows these various electrical components, which are high-voltage components, to be housed in an enclosed space, protected from external pollution, particularly from water and / or dust. Furthermore, any accidental contact between these high-voltage electrical components and the environment is limited, if not eliminated, the risk of electrocution for a user.

[0072] Each input terminal 38 is respectively electrically connected to one of the output connectors 30, in order to be electrically powered by the output connectors 30. The input terminal 38 connected to the positive output connector 30 is said to be the positive input terminal, and the input terminal 38 connected to the negative output connector 30 is said to be the negative input terminal.

[0073] The connection between the output connectors 30 and the input terminals 38 is made within the internal space of the V20 module. This remarkably allows for high-voltage electrical connections to be made in a closed, sealed space, isolated from the external environment. This greatly improves safety by preventing any risk of water, dust, or hydrogen intrusion, or even any contact of a foreign object with the connectors 30 and the input terminals 38. Furthermore, this prevents electrical cables from protruding from the first and second enclosures 34 and 46, thus eliminating any risk of them being pulled out or damaged.

[0074] The arrangement of the output connectors 30 and input terminals 38, in the internal space of the V20 module, as well as the connection method, may vary.

[0075] For example, as shown in Figures 2 to 5, the output connectors 30 and the input terminals 38 are advantageously arranged respectively in the internal volume V34 and the internal volume V46, and are also opposite the opening 60 in the Z-direction. The output connectors 30 and the input terminals 38 are spaced apart, and the electrical connection between the output connectors 30 and the input terminals 38 is made indirectly, via an intermediate connection device 62. The intermediate connection device 62 is located entirely within the internal space of module V20 and connects the output connectors 30 and the input terminals 38 through the opening 60.

[0076] The intermediate connection device 62 is, for example, formed of two rigid bars. One rigid bar 62 is, for example, connected to the positive output connector 30 and input terminal 38, and the other is, for example, connected to the negative output connector 30 and input terminal 38, e.g., by being screwed to their respective output connector 30 and input terminal 38. One of the bars 62 is shown in detail in Figure 5. In an alternative configuration not shown, the intermediate connection device 62 comprises flexible cables, which replace the rigid bars 62.

[0077] Alternatively, the output connectors 30 and / or the input terminals 38 are arranged in the connection space V56, for example, within the opening 60. Alternatively, the opening 60 is either absent or passes through only one of the enclosures 34 or 46, and the output connectors 30 and / or the input terminals 38 protrude directly from the enclosure 34 and / or 46 into the connection space V56. The electrical connection between the input terminals 38 and the output connectors 30 is made via the intermediate connection device 62, or directly, i.e., via direct contact between the input terminals 38 and the output connectors 30. In this case, there is no intermediate connection device.

[0078] The power supply system 10 advantageously includes a cooling circuit 70. The cooling circuit 70 is advantageously configured to circulate a coolant through the fuel cell 24, as can be seen in Figure 2.

[0079] Advantageously, the cooling circuit 70 includes a main circuit 71, or main cooling circuit, which includes an inlet of the coolant into the fuel cell 24, and an outlet of the coolant into the fuel cell 24.

[0080] The cooling circuit 70 advantageously includes an auxiliary cooling circuit 71a, which includes an auxiliary coolant intake line 72, separate from the main circuit 71.

[0081] Preferably, the auxiliary cooling line 72 is independent of (i.e., not connected to) the main circuit 70.

[0082] Alternatively, the auxiliary cooling line 72 is connected for example downstream of the coolant outlet in the fuel cell 24, as shown in dotted line in figure 2.

[0083] The auxiliary coolant intake line 72 is fluidly connected to the coolant inlet 48. When the fuel cell 24 is in operation, the coolant thus circulates in the power conversion unit 36, in order to cool the latter.

[0084] The coolant outlet 49 is fluidly connected to the cooling circuit 70.

[0085] Preferably, the auxiliary cooling circuit 71a further comprises an auxiliary outlet line 73. The auxiliary outlet line fluidly connects the coolant outlet 49 to the auxiliary coolant intake line 72. In this case, the auxiliary outlet line 73 is independent of (i.e. not connected to) the main circuit 71, in particular is independent of a cooling line of the main circuit 71.

[0086] Alternatively and optionally, the auxiliary outlet line 73 fluidly connects the coolant outlet 68 and the main circuit 71, for example downstream of the auxiliary coolant intake line 72, so that the fluid reinjected into the main circuit 71 by the auxiliary outlet line 73 is downstream of the auxiliary coolant intake line 72. This is represented by dashed lines in Figure 2.

[0087] Circuit 70 may include additional components, such as heat exchangers, tanks, valves or pumps, not shown.

[0088] Thus, thanks to this auxiliary cooling circuit 71a, including in particular the auxiliary coolant inlet 72 connected to the coolant inlet 48, and the auxiliary outlet line 73 connected to the coolant outlet 49, it is possible to easily and efficiently cool the power conversion unit 36. As mentioned previously, this auxiliary cooling circuit 71a can either be independent of the main cooling circuit 71, which allows for independent cooling temperatures, or connected to the main cooling circuit 71, as represented by the dotted lines in Figure 2, which allows for a simpler structure and minimizes the number of hoses required.

[0089] Advantageously, the power supply system 10 further includes an air circuit 80 and a hydrogen circuit (not shown) configured to supply the fuel cell 24 with air and hydrogen, respectively. The cooling circuit 70 further includes a heat exchanger 82 connected to the auxiliary cooling supply line 72 and to the air circuit 80, for example, to cool the air supplying the fuel cell 24 after it has been pressurized by a compressor (not shown). The heat exchanger 82 is, for example, located at an air inlet 84 of the air circuit 80.

[0090] The motor 12 is connected to the output terminals 44, either directly, for example via busbars connected only to the output terminals 44 and to the motor 12, in order to be electrically supplied via the output terminals 44, or indirectly.

[0091] In the case where the motor 12 is indirectly connected to the output terminals 44, the battery 14 is advantageously connected between the output terminals 44 and the motor 12, as shown in Figure 2. In particular, a battery connection device 86, such as cables, is connected between the output terminals 44 and the battery 14, the battery 14 also being electrically connected to the motor 12, for example via a cable 87 in order to supply power to the motor 12. The power supply module 20 is then configured to supply an electrical current to the motor 12 via the battery 14.

[0092] According to an alternative (not shown), the motor 12 is connected to the output terminals 44 by two different devices: one that allows the motor 12 to be directly connected to the output terminals 44, and another that allows the motor 12 to be connected to the battery 14, and thus indirectly connected to the output terminals 44. When the system 20 is operating, the fuel cell 24 is supplied with air, via the air circuit 80, with hydrogen via the hydrogen circuit, and with coolant via the cooling circuit 70. The stack 26 generates an electric current. The electric current generated by the stack 26 is advantageously a direct current, with a voltage on the order of a few hundred volts, for example, on the order of 400V.

[0093] Electric current flows through electrodes 28 and cables 32 to output connectors 30. The current then flows through input terminals 38 via intermediate connection device 62, then through cables 50 to input 40a of converter 40 to supply converter 40 with electricity.

[0094] The converter 40 converts the electrical current into a current of a different voltage. For example, the converter 40 reduces the voltage to provide a current of approximately 200 to 300V, for example, 270V. Alternatively, the converter 40 increases the voltage to provide a current of approximately 400 to 1200V, for example, 800V. The current flows from the converter's output 40b, through cables 52, output terminals 44, and the battery connection device 86 to the battery 14, for example, to charge the battery 14. The battery 14 then supplies electrical current to the motor 12, for example, to power the vehicle 1.

[0095] The switch 42 is controlled by the control unit 49 in order to adapt the operation of the converter 40 according to the needs of the vehicle 1, more specifically of the battery 14 and / or the motor 12.

[0096] The electrical conversion carried out by the converter 40 can generate heat. Thus, to avoid an excessive increase in temperature, which could damage the equipment or have a negative impact on the operation of the system 10, the cooling fluid, which in the example of figures 2 to 5 is coolant, circulates in the power conversion unit 36 ​​from the cooling circuit 70, or preferably only from the auxiliary circuit 71a.

[0097] For example, the coolant circulates through the fuel cell 24, and then, once it exits the fuel cell 24, some of the coolant is diverted to circulate in the auxiliary coolant intake line 72. The remainder of the coolant continues to circulate in the main circuit 71. The coolant circulating in the auxiliary coolant intake line 72 flows through the heat exchanger 82, then into the coolant inlet 48. The coolant flows through the power conversion unit 36, then into the cooling outlet 49, before being reinjected into the main circuit 71 via the auxiliary outlet line 73. The direction of coolant flow is indicated by arrows.

[0098] Alternatively, and preferably, only the auxiliary cooling circuit 71a is dedicated to cooling the power conversion unit 36, and possibly to cooling other auxiliaries of the system 10. In this case, the coolant flows in the auxiliary coolant intake line 72, through the heat exchanger 82, into the coolant inlet 48, into the power conversion unit 36, then into the cooling outlet 49 before being reinjected into the auxiliary coolant intake line 72 via the auxiliary outlet line 73.

[0099] A method for assembling the power supply module 20 is described below. The method advantageously includes a step S102 for positioning the casing 34. More specifically, in step S102, the casing 34 is positioned such that the lower face 34a is located above the upper face 34b. In other words, a distance measured along the vertical direction V between the floor surface S and the upper face 34b is less than the distance measured along the vertical direction V between the floor surface S and the lower face 34a. This facilitates the subsequent positioning of the seal 56 on the lower face 34a of the casing 34, the lower face 34a then being "upward" (or "suspended").

[0100] A positioning step S104 of the seal 56 is advantageously carried out following step S102. During the positioning step S104, the seal 56 is positioned on the lower face 34a of the casing 34.

[0101] A step S106 of alignment and bringing together the lower face 34a of the casing 34 and the upper face 46a of the casing 46 is then carried out. Advantageously, at the end of the alignment and bringing together step S106, the upper face 46a and the lower face 34a are superimposed along the vertical direction V, and less than one meter apart along the vertical direction V.

[0102] A step S108 of connecting the output connectors 30 to the input terminals 38 is then carried out in the connection space V56. The connection step S108 is carried out for example by screwing the bars forming the intermediate connection device 62 respectively to one of the output connectors 30 and to one of the input terminals 38. Alternatively, connecting cables are used.

[0103] A step S110, bringing the seal 56 into contact with the upper face 46a, is performed following step S108. Alternatively, step S108 is performed simultaneously with step S110. This is particularly the case if the output connectors 30 and the input terminals 38 are in direct contact with each other.

[0104] A step S112 is then performed to attach the power generation unit 22 and the power conversion unit 36 ​​to form the module 20. For example, the power generation unit 22 and the power conversion unit 36 ​​are screwed together. Following step S112, the power conversion unit 36 ​​is positioned on top of the power generation unit 22.

[0105] Advantageously, the process also includes a reversing step S114, carried out after the fixing step S112 has been completed. During the reversing step S114, the module 20 is reversed so that the power generation unit 22 is positioned on the power conversion unit 36.

[0106] Alternatively, during the disposition step S104, the seal 56 is disposed on the upper face 46a of the envelope 46, and during the contacting step S110, the seal 56 is brought into contact with the lower face 34a.

[0107] In the variant not shown, the process only includes steps S104 to S112.

[0108] Such a process makes it possible to significantly reduce the time and complexity of assembling system 10. Indeed, thanks to the invention, all the connectors and connection operations are concentrated and limited to the interior space of module V20: it is therefore easy and quick for an operator to concentrate his activities locally in this space.

[0109] A second embodiment of a system 100 according to the invention is shown in Figure 7. Identical elements between systems 10 and 100 are referenced with the same reference symbols and are not described again in detail.

[0110] System 100 differs from system 10 in that it includes a cooling circuit 170 which replaces the cooling circuit 70 and an air circuit 180 which replaces the air circuit 80.

[0111] The cooling circuit 70 is not fluidly connected to the power conversion unit 36, and serves only to cool the fuel cell 24.

[0112] The air circuit 180 is configured to circulate air in the fuel cell 24. For this purpose, it includes an air inlet 183 and an air outlet 184. The air circuit 180 further includes a compressor 186 and preferably a heat exchanger, not shown, to cool the compressed air, fluidly connected to and downstream of the air inlet 183, and an auxiliary air intake line 188, fluidly connected to the cooling fluid inlet 48 and connected downstream of the air inlet 183, advantageously downstream of the compressor 186 and the heat exchanger.

[0113] The air circuit 180 further includes an air exhaust line 190, fluidly connected to the coolant outlet 49 and to the air outlet 184.

[0114] The operation of system 100 is identical to that of system 10 except for the differences described below.

[0115] In order to cool the power conversion unit 36, cooling fluid, which in the example of Figure 7 is air, circulates in the power conversion unit 36 ​​from the air circuit 180. For example, the air flows into the air inlet 183, and is compressed by the compressor 186, then preferentially cooled by a heat exchanger. At the outlet of the compressor 186 and preferably of the heat exchanger, part of the air is diverted into the air intake line 188, up to the coolant inlet 48 and circulates in the power conversion unit 36. The air circulating in the power conversion unit 36 ​​is then discharged via the coolant outlet 49, the air discharge line 190 to the air outlet 184. The direction of air flow is shown in Figure 7 by arrows.

[0116] The remaining air circulates through the fuel cell to supply it with oxygen, then is evacuated from the fuel cell 24 to the air outlet 184.

[0117] Thus, regardless of the embodiment chosen, when system 10 or 100 is integrated into vehicle 1, the power generation unit 22 is stacked on top of the power conversion unit 36, that is, it is above the power conversion unit 36. Therefore, despite the presence of the opening 60, any hydrogen present in the internal volume V34 has little, if any, risk of diffusing into the internal volume V46, since hydrogen is lighter than the air present in the internal space of module V20. It therefore tends to rise and thus remain in the internal volume V36. Consequently, the risk of explosion in the internal volume V46 of the power conversion unit 36 ​​is considerably reduced, thereby increasing the overall safety of system 10.

[0118] Furthermore, systems 10 and 100 feature optimized dimensions and minimize the presence of cables or connection devices outside the internal space of module V20. This reduces the risk of damage caused by external elements or handling, as well as safety hazards, such as those caused by unintentional contact between the intermediate connection device 62 and another vehicle component. Finally, the seal 56 ensures that the internal space of module V20 is watertight, airtight, and free from external particles, thus guaranteeing a secure electrical connection that will not deteriorate over time. In addition, the assembly of the power module 20 is simplified and faster, as it eliminates the need to connect individual cables between the power generation unit 22 and the power conversion unit 36.

[0119] Any feature described for an embodiment or variant in the foregoing may be implemented for the other embodiments and variants described above, provided that it is technically feasible.

Claims

DEMANDS 1. Power supply module (20) for a vehicle (1), the power supply module (20) comprising: a power generation unit (22), comprising: o a fuel cell (24), comprising current collection electrodes (28); o output connectors (30), each current collection electrode (28) being respectively electrically connected to one of the output connectors (30); o a first enclosure (34), the fuel cell (24) being disposed in the first enclosure (34), a power conversion unit (36), comprising: o input terminals (38), each input terminal (38) being respectively connected to one of the output connectors (30) in order to be electrically supplied; o an electrical converter (40) having an input (40a) connected to the input terminals (38) in order to be electrically supplied via the input terminals (38);o a power switch (42), connected to the electrical converter (40), configured to interrupt or allow an electric current to flow through the converter (40);o output terminals (44), connected to an output of the electrical converter (40b) and configured to be connected to an electric traction motor (12) of the vehicle (1) in order to electrically power the electric traction motor (12), o a second enclosure (46), the converter (40) and the power switch (42) being arranged in the second enclosure (46), the power generation unit (22) being stacked on the power conversion unit (36) in a height direction (Z), the power generation (22) and power conversion (36) units being fixed to each other, characterized in that the power supply module (20) further comprises a seal (56) forming a closed loop, interposed between an upper face (46a) of the second enclosure (46) and a lower face (34a) of the first enclosure (34) in the direction; height (Z), the joint (56) and the upper (34a) and lower (46a) faces delimiting a connection space (V56), and in that the connection between the output connectors (30) and the input terminals (38) is made in an internal module space (V20), formed of an internal volume (V34) of the first envelope (34), an internal volume (V46) of the second envelope (46) and the connection space (V56).

2. Module (20) according to claim 1, wherein the output connectors (30) and the input terminals (38) are spaced apart from each other and electrically connected by an intermediate connection device (62), located entirely within the internal space of the module (V20).

3. Module (20) according to claim 1 or 2, comprising an opening (60), passing through the lower face (34a) of the first envelope (34) and upper face (46a) of the second envelope (46), at the level of the connection space (V56), and in which the output connectors (30) and the input terminals (38) are opposite the opening (60) in the height direction (Z) and electrically connected through the opening (60).

4. Module (20) according to any one of claims 1 to 3, wherein a height (Z36) of the power conversion unit (36), measured from the top face (46a) in a direction (Z') opposite to the height direction (Z), is less than a height (Z22) of the power generation unit (22), measured from the bottom face (34a) in the height direction (Z), preferably less than two-thirds of the height (Z22) of the power generation unit (22), preferably less than or equal to half the height (Z22) of the power generation unit (22).

5. Module (20) according to any one of claims 1 to 4, wherein a length (X22) of the power generation unit (22), measured along a length direction (X), perpendicular to the height direction (Z), is equal to a length (X36) of the power conversion unit (36), measured along the length direction (X).

6. Module (20) according to claim 5, wherein a width (Y22) of the power generation unit (22), measured along a width direction (Y), perpendicular to the height (Z) and length (X) directions, is equal to a width (Y36) of the power conversion unit (36), measured along the width (Y) direction.

7. Module (20) according to any one of claims 1 to 6, wherein the power conversion unit (36) includes a coolant inlet (48) and a coolant outlet (49), in order to cool the internal volume (V46) of the power conversion unit (36).

8. Power system (100) comprising a power module (20) according to claim 7, the coolant being air, and further comprising an air circuit (180), configured to circulate air into the fuel cell (24), the air circuit (180) comprising an air inlet (183), and an auxiliary air intake line (188) fluidically connected downstream of the air inlet (183) and fluidly connected to the coolant inlet (48).

9. System (100) according to claim 8 further comprising a compressor (186) fluidly connected to, and downstream of, the air inlet (183), the auxiliary air intake line (188) being connected downstream of the compressor (186).

10. System (10) comprising a power module (20) according to claim 7, the cooling fluid being a coolant, and further comprising a cooling circuit (70), comprising an auxiliary cooling circuit (71a) comprising an auxiliary coolant intake line (72) fluidly connected to the coolant inlet (48).

11. System (10) according to claim 10 further comprising a heat exchanger (82) connected to the auxiliary cooling outlet line (72) and to an air circuit (80) supplying the fuel cell (24).

12. Vehicle (1) comprising: a system (10; 100) according to any one of claims 8 to 11; an electric traction motor (12) of the vehicle (1), supplied with electric current by the power supply module (20) via the output terminals (44), and wherein when the vehicle (1) is placed on a ground surface (S), the height direction (Z) is perpendicular to the ground surface (S) and directed away from the ground surface (S).

13. Vehicle (1) according to claim 12, further comprising a battery (14), electrically connected to the output terminals (44) by a battery connection device (86), and electrically connected to the electric traction motor (12), so that the electric traction motor (12) is supplied by the power module (20) via the output terminals (44), via the battery (86).

14. Method of assembling a power supply module (20) according to any one of claims 1 to 7, the method comprising the following steps: positioning (S104) the seal (56) on one face among the lower face (34a) of the first enclosure (34) and on the upper face (46a) of the second enclosure (46); alignment and bringing together (S106) the lower face (34a) of the first enclosure (34) and the upper face (46a) of the second enclosure (46); connection (S108) of the output connectors (30) to the input terminals (38) in the connection space (V56); bringing into contact (S110) the seal (56) and another face among the lower face (34a) of the first enclosure (34) and the upper face (46a) of the second enclosure (46); and fixing (S112) of the power generation unit (22) and of the conversion unit (36).

15. Assembly method according to the preceding claim wherein the positioning step (S104) of the seal (56) comprises the positioning of the seal (56) on the lower face (34a) of the first casing (34), the method further comprising: a preliminary positioning step (S102) of the first casing (34), such that the lower face (34a) is positioned above an upper face (34b) of the first casing (34), the upper face (34b) being parallel to the lower face (34a); and the fixing step (S112) of the power generation unit (22) and the conversion unit (36) having been carried out, a reversing step (S114) of the module (20), such that the power generation unit (22) is positioned on the power conversion unit (36).

Images