Tubular element for a heat exchanger

Abstract

A tubular element for a heat exchanger, including: a primary tank, a secondary tank, a tube extending between the primary tank and the secondary tank, the tubular element being configured to enable fluid flow within the tubular element between the primary tank and the secondary tank. The primary tank includes a primary tank hanging assembly configured to enable hanging the tubular element on a base element. The secondary tank includes a secondary tank hanging assembly configured to enable hanging a bottom element on the tubular element.

Description

TUBULAR ELEMENT FOR A HEAT EXCHANGERTECHNICAL FIELD

[0001] The present invention pertains to a tubular element designed for use in a heat exchanger, particularly for regulating the temperature of an electric device, such as a batten in a vehicular system.BACKGROUND OF THE INVENTION

[0002] A critical component of electric vehicle technology is the battery pack, which serves as the pri ary energy storage system. Among various batten formats, cylindrical, e.g. lithium-ion, cells are widely used due to their high energy density, structural stability, and efficient packing configuration.

[0003] Thermal management of these battery packs is essential to ensure optimal performance, safety, and longevity. During operation, battery cells generate significant heat, particularly during high discharge rates or rapid charging. Conversely, in cold conditions, batteries may require heating or conditioning to maintain efficient and prevent capacity loss due to low temperatures.

[0004] Effective cooling is required to prevent overheating, which can lead to reduced efficiency, accelerated degradation, or even thermal runway in extreme cases, while active heating systems are necessary to ensure consistent performance in suboptimal thermal environments.

[0005] Heat exchangers are commonly employed in battery systems to manage temperature. These systems often rely on tubular elements to circulate a heat exchange fluid for heat dissipation. The design of these tubular elements is crucial to achieving uniform and efficient cooling across the densely packed cylindrical cells in a battery module.

[0006] Undulated tubes have emerged as an effective solution for improving heat transfer in such applications. The wavy geometry promotes turbulence in the heat exchange fluid flow, increasing the efficiency of heat exchange between the surface and the fluid. Additionally, wavy tubes are adaptable to the complex geometries of battery packs, ensuring consistent cooling across all cells and reducing the risk of localized hotspots.

[0007] There remains a need for a tubular element specifically optimized for use in heat exchangers for cylindrical battery packs in electric vehicles. Such a solution should address thedual objectives of enhancing heat dissipation and conforming to the compact and intricate design requirements of modem battery systems. This invention aims to fulfill these needs.SUMMARY OF THE INVENTION

[0008] An object of the invention is a tubular element for a heat exchanger, including: a primary tank, a secondary tank, a tube extending between the primary tank and the secondary tank, the tubular element being configured to enable fluid flow within the tubular element between the primary tank and the secondary tank, wherein the primary tank includes a primary' tank hanging assembly configured to enable hanging the tubular element on a base element, wherein the secondary tank includes a secondary tank hanging assembly configured to enable hanging a bottom element on the tubular element.

[0009] In one option, the secondary tank hanging assembly includes a first side secondary tank opening and a second side secondary tank opening.

[0010] In one option, the first side secondary tank opening and the second side secondary tank opening have continuous and uninterrupted sidewalls.

[0011] In one option, the first side secondary' tank opening and the second side secondary tank opening each include a narrower portion and a wider portion, wherein the narrower portions are facing each other.

[0012] In one option, the first side secondary tank opening and the second side secondary tank opening are tear-shaped.

[0013] In one option, the first side secondary tank opening and the second side secondary tank opening have non -continuous sidewalls.

[0014] In one option, the first side secondary' tank opening and the second side secondary' tank opening are defined in part respectively by a first ami and a second ami, both extending from the secondary tank.

[0015] In one option, the primary tank hanging assembly includes a first side primary tank opening and a second side primary tank opening.

[0016] In one option, the first side primary tank opening and the second side primary tank opening each include a narrower portion and a wider portion, wherein the narrower portions are facing each other.

[0017] In one option, the first side primary tank opening and the second side primary tank opening are triangle-shaped.

[0018] In one option, the primary tank hanging assembly includes a middle primary tank opening.

[0019] In one option, the middle primary tank opening is round.

[0020] In one option, the middle primary tank opening includes an elongated portion and an enlarged portion extending perpendicularly from the elongated portion towards the tube.

[0021] In one option, the tube extends along a meandering path between the primary tank and tire secondary tank.

[0022] In one option, the primary tank is formed from two shaped portions connected to each other.

[0023] In one option, the two shaped portions are connected to each other by crimping tabs present on at least one of the two shaped portions.

[0024] In one option, the two shaped portions arc brazed to each other and the tube.BRIEF DESCRIPTION OF DRAWINGS

[0025] The present invention will be described in greater detail below with reference to the drawings. In the drawings:

[0026] Fig. 1 shows a tubular element in a perspective view;

[0027] Fig. 2 shows the primary tank of the tubular element in a perspective view;

[0028] Fig. 3 shows the secondary tank of the tubular element in a perspective view;

[0029] Fig. 4 shows a rack assembly with a plurality of tubular elements:

[0030] Fig. 5 shows a closer view at a base element of the rack assembly;

[0031] Fig. 6 shows a closer view at a bottom element of the rack assembly;

[0032] Fig. 7 shows another example of the primary tank of the tubular element in a perspective view;

[0033] Fig. 8 shows the primary tank of Fig. 7 in top view; and

[0034] Fig. 9 shows another example of the secondary tank in a perspective view.DETAILED DESCRIPTION OF THE INVENTION

[0035] Fig. 1 shows a tubular element 1 for a heat exchanger in a perspective view, with Fig. 2 and Fig. 3 showing respectively a primary tank 10 and a secondary tank 20 of the tubular element 1 in closer views. Tire tubular element 1 comprises a primary tank 10 and a secondary tank 20. A tube 30 extends between the primary tank 10 and the secondary' tank 20. The primary' tank 10, the secondary tank 20 and the tube 30 are configured so as to provide U-flow for the fluid within the tubular element 1. The primary tank 10 can be a distribution tank. The secondary’ tank 20 can be a return tank. The tube 30 can be a flat, wavy tube, to maximize the surface area in contact with the battery cell. Tire U-flow arrangement refers to the coolant flow pattern where fluid enters the tube 30, travels in one direction to the end, and then reverses its path in the opposite direction within the same tube. This creates ac'U”-shaped flow path within the flat tube, which is designed to optimize heat exchange performance and flow uniformity.

[0036] Tire primary' tank 10 includes an inlet chamber 11 with an inlet connector 14, as well as an outlet chamber 12 with an outlet connector 15. The inlet chamber 11 is separated from the outlet chamber 12 within the primary tank 10. The heat exchange fluid enters the tube 30 and flows along the first leg of the U-path, absorbing heat from the battery cell through the flat surface or giving the heat away to the cell.

[0037] The secondary tank 20 ensures flow reversal, in a sense that the heat exchange fluid is redirected to flow back along the second leg of the U-path, further enhancing heat exchange. The heat exchange fluid exits the tube 30 after completing the U-path.

[0038] Tire tube 30 extends along a meandering path between the primary tank 10 and the secondary tank 20.

[0039] The tube 30 can be extruded. The tube 30 can be of aluminum.

[0040] The primary tank 10 can be formed from two shaped portions 16 connected to each other.The two shaped portions 16 can be connected to each other by crimping tabs 17 present on at least one of the two shaped portions 16.

[0041] Tire tube 30 can include a set of inlet channels and a set of outlet channels. The set of inlet channels can lead tire fluid from the primary tank 10 to the secondary tank 20. Tire set of outlet channels can lead the fluid from the secondary tank 20 to the primary tank 10. In other words, both the set of inlet channels and the set of outlet channels can terminate in the primary tank 10 and the secondary tank 20.

[0042] Fig. 4 shows a rack assembly 60 with a plurality of tubular elements 1, with Fig. 5 showing a closer view at a base element 61 of the rack assembly 60 and Fig. 6 showing a closer view at a bottom element 63 of the rack assembly 60.

[0043] Tire rack assembly 60 can include a top hanger 65 for hanging on another element, for example an attachment point of a conveyer.

[0044] In general, tire tubular elements 1 can be spray coated with dielectric material. A uniform layer of insulation can be applied by atomization of the coating material into fine droplets and deposition onto the surface of the tubular component 1. The material that can be used for this purpose can be epoxy, polyurethane, polyimide, or silicone-based coatings. An adequate material can be selected for its electrical insulation and chemical resistance properties. A specialized spray gun or a set of spray guns, for example with electrostatic capability, can be used to atomize the coating material into a fine mist. Since an even and uniform application of the material is crucial, it can be important to stabilize the tubular elements 1 during the process.

[0045] For this purpose, as shown in Fig. 2 and Fig. 3, the primary tank 10 includes a primary tank hanging assembly 40 configured to enable hanging the tubular element 1 on the base element 61 , while the secondary tank 20 includes a secondary tank hanging assembly 50 configured to enable hanging a bottom element 63 on the tubular element 1.

[0046] Hanging the tubular element 1 vertically from the base element 61 and providing a two- point attachment for the bottom element 63 enables stabilizing tire tubular elements 1 during coating and / or transport between various stages in the manufacturing process. This is particularly advantageous where the rack assembly 60 is used to handle a plurality of tubular elements 1 at once, and where the rack assembly 60 with the tubular elements 1 is moved, for example by means of an automated conveyor between various stations of the manufacturing line. Such arrangement limits swaying and rotation of tubular elements 1, which nonnally could result in degraded quality of coating application.

[0047] The primary tank hanging assembly 40 can include a first side primary tank opening 41 and a second side primary tank opening 42.

[0048] The first side primary7tank opening 41 and the second side primary tank opening 42 can each include a narrower portion 73 and a wider portion 74, wherein the narrower portions 73 are facing each other.

[0049] The first side primary tank opening 41 and the second side primary tank opening 42 can be triangle-shaped.

[0050] Tire primary tank hanging assembly 40 can include a middle primary tank opening 43. In such case, the middle primary' tank opening 43 preferably is located centrally with respect to the primary tank 10, e.g. between the inlet chamber 11 and the outlet chamber 12.

[0051] The base element 61 can include a plurality of base element hooks 62, so that a plurality of tubular elements 1 can be hanged at tire same time. Each tubular element 1 can require one base element hook 62, for example when only middle primary tank opening 43 will be used to hang the tubular element 1. Alternatively, each tubular element 1 can require two base element hooks 62, for example when the first side primary' tank opening 41 and the second side primary' tank opening 42 will be used to hang the tubular element 1.

[0052] The middle primary tank opening 43 can be round.

[0053] The secondary tank 20 includes a secondary tank hanging assembly 50 configured to enable hanging a bottom element 63 on the tubular element 1.

[0054] The secondary tank hanging assembly 50 can include a first side secondary tank opening 51 and a second side secondary tank opening 52.

[0055] Tire bottom element 63 can include a plurality of bottom element hooks 64. Each tubular element 1 can require two bottom element hooks 64, for example when the first side secondary' tank opening 51 and the second side secondary tank opening 52 will be used to hang tire bottom element 63 on the tubular element 1.

[0056] The first side secondary tank opening 51 and the second side secondary tank opening 52 can have continuous and uninterrupted sidewalls 55. In other words, the first side secondary tank opening 51 and the second side secondary' tank opening 52 can be holes.

[0057] Tire first side secondary' tank opening 51 and tire second side secondary tank opening 52 can each include a narrower portion 73 and a wider portion 74, wherein the narrower portions 73 can be facing each other.

[0058] For example, the first side secondary tank opening 51 and the second side secondary tank opening 52 can be tear-shaped.

[0059] Fig. 7 shows another example of the primary tank 10 of the tubular element 1 in a perspective view, while Fig. 8 shows the primary tank 10 of Fig. 7 in top view.

[0060] The middle primary tank opening 43 can include an elongated portion 44 and an enlarged portion 45 extending perpendicularly from the elongated portion 44 towards the tube 30, as opposed to being round.

[0061] Fig. 9 shows another example of the secondary tank 20 in a perspective view.

[0062] Tire first side secondary tank opening 51 and tire second side secondary tank opening 52 can have non-continuous sidewalls 55. In other words, it is possible for the bottom element hooks 64 to enter tire first side secondary tank opening 51 and the second side secondary tank opening 52 from a side, and not only from the direction perpendicular to the secondary tank 20.

[0063] For example, the first side secondary tank opening 51 and the second side secondary tank opening 52 can be defined in part respectively by a first arm 53 and a second arm 54, both extending from the secondary tank 20. This can allow reducing material necessary for the secondary' tank 20 and consequently reducing the overall cost of the tubular element 1.

Claims

Claims1. A tubular element for a heat exchanger, comprising: a rimary tank, a secondary tank, a tube extending between the primary tank and tire secondary tank, the tubular element being configured to enable fluid flow within the tubular element between the primary tank and the secondary tank, wherein the primary tank includes a primary tank hanging assembly configured to enable hanging the tubular element on a base element, wherein the secondary tank includes a secondary tank hanging assembly configured to enable hanging a bottom element on the tubular element.

2. The tubular element according to claim 1, wherein the secondary tank hanging assembly includes a first side secondary tank opening and a second side secondary tank opening.

3. The tubular element according to claim 2, wherein the first side secondary tank opening and the second side secondary tank opening have continuous and uninterrupted sidewalls.

4. The tubular element according to claim 2, wherein the first side secondary tank opening and the second side secondary' tank opening each include a narrower portion and a wider portion, wherein the narrower portions are facing each other.

5. The tubular element according to claim 4, wherein the first side secondary tank opening and the second side secondary tank opening are tear-shaped.

6. The tubular element according to claim 2, wherein tire first side secondary tank opening and the second side secondary tank opening have non-continuous sidewalls.

7. The tubular element according to claim 6, wherein the first side secondary' tank opening and the second side secondary tank opening are defined in part respectively by a first arm and a second ami, both extending from the secondary' tank.

8. The tubular element according to claim 1, wherein the primary tank hanging assembly includes a first side primary tank opening and a second side primary tank opening.

9. Tire tubular element according to claim 8, wherein the first side primary tank opening and the second side primary tank opening each include a narrower portion and a wider portion, wherein the narrower portions are facing each other.

10. The tubular element according to claim 9, wherein the first side rimary tank opening and the second side primary tank opening are triangle-shaped.

11. The tubular element according to claim 1, wherein the primary tank hanging assembly includes a middle primary tank opening.

12. The tubular element according to claim 11, wherein the middle rimary tank opening is round.

13. The tubular element according to claim 11, wherein the middle primary tank opening includes an elongated portion and an enlarged portion extending perpendicularly from the elongated portion towards the tube.

14. The tubular element according to claim 1, wherein the tube extends along a meandering path between the primary tank and the secondary tank.

15. The tubular element according to claim 1, wherein the primary tank is fonned from two shaped portions connected to each other.

16. The tubular element according to claim 12, wherein the two shaped portions are connected to each other by crimping tabs present on at least one of tire two shaped portions.

17. The tubular element according to claim 1 , wherein the two shaped portions are brazed to each other and the tube.

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