Modular heat exchange system applied to a battery module and method for manufacturing same

Abstract

The present invention describes a modular heat exchange system applied to a battery module and a method for manufacturing same. Specifically, the present invention comprises a modular heat exchange system applied to the base of the battery module, formed by a set of plates designed to make it possible to adjust and customize the configuration thereof according to the size, capacity, and / or geometric configuration of the battery pack, making it possible for different battery modules to be cooled and / or heated by means of the present system. Furthermore, the plates of the system comprise internal fluid circulation channels provided with fins and flanges that maximize the heat exchange between the fluid and the plates, improving the energy efficiency of the system. The present invention pertains to the fields of electrical engineering and mechanical engineering, relating to the area of heat exchange systems for automotive batteries and electric power systems.

Description

MODULAR THERMAL EXCHANGE SYSTEM APPLIED TO A BATTERY MODULE AND ITS MANUFACTURING PROCESS Field of Invention

[0001] The present invention describes a modular heat exchange system applied to a battery module, a manufacturing process thereof, a vehicle comprising at least one battery module, and a heat exchange system and battery module kit. The present invention is situated in the fields of electrical engineering and mechanical engineering, focused on the area of ​​heat exchange systems for automotive batteries and electrical power systems. Background of the Invention

[0002] Battery cooling systems are widely used in electric vehicles (EVs) and hybrid vehicles (HEVs) to maintain battery temperatures within an ideal range. Furthermore, battery thermal management is fundamental to ensuring battery performance, longevity, and safety, making cooling systems crucial to the overall operation of the battery pack.

[0003] In current cooling systems, it is common to use air as a cooling fluid, where air circulation is used to dissipate the heat generated by the batteries during charging and discharging.

[0004] However, these air-cooled systems have low efficiency, since the heat dissipation capacity of air systems is limited. Under high energy demand conditions, it can be difficult to maintain the battery within the ideal temperature range, especially in hot and cold climates when there is a need to heat the battery to the optimal operating point. Similarly, precise temperature control is difficult, and the system's effectiveness can vary significantly depending on environmental conditions such as air temperature and humidity.

[0005] Furthermore, many current cooling systems have elements and components that make assembly with the battery pack difficult, and they also lack configurable geometry that allows for customizing the configuration and quantity of cooling systems according to the number of batteries in the pack.

[0006] Furthermore, current battery cooling systems are manufactured from heavy metal alloys, which considerably increases the overall weight of the vehicle.

[0007] In the search for the state of the art in scientific and patent literature, the following documents were found that address the topic:

[0008] Document DE202024103342U1 presents a battery cooling base manufactured from aluminum by an extrusion process, provided with finned flow channels for fluid passage and a fluid inlet and outlet. The fins of the flow channel are arranged alternately and project from the upper and lower walls of the channel. Furthermore, the fins are manufactured by extrusion and can have different sizes or densities and can be arranged in different areas of the plate. However, document DE202024103342U1 does not disclose a heat exchange base for batteries with a geometry comprising fluid passage channels with fins arranged symmetrically to each other, projecting from the upper and lower inner walls of each channel, nor does it disclose a specific geometry with a structure for fixing the heat exchange base to the vehicle, the base to the battery module, and a cover for the battery.

[0009] Document US2022107145A1 presents a battery cooling base consisting of a plate with a flow channel, the plate being manufactured by an aluminum extrusion process. Inside the channel, there is a raised section with fins that act as turbulators, causing the fluid to rotate as it flows through the channel. Furthermore, the channel fins project from the lower wall of the channel. However, document US2022107145A1 does not disclose a heat exchange base with a specific geometry comprising fluid passage channels with fins arranged symmetrically to each other, projecting from the upper and lower inner walls of each channel, nor does it disclose a geometry with a structure for attaching the heat exchange base to the vehicle, the base to the battery module, and a cover for the battery.

[0010] Document US20190207280A1 discloses a metal battery cooling base manufactured by an extrusion process, provided with one or more interconnected plates and a top plate. The plates have channels with spaced internal flanges. However, document US20190207280A1 does not disclose a heat exchange base with a geometry comprising fluid passage channels with fins arranged symmetrically to each other, projecting from the upper and lower inner walls of each channel, nor does it disclose a specific geometry with a structure for attaching the heat exchange base to the vehicle, the base to the battery module, and a cover to the battery.

[0011] Document US2023074724A1 discloses a battery cooling plate manufactured from aluminum through extrusion, stamping / forming, or casting processes. Said plate is provided with channels separated by walls, where the channels can have any geometric shape and can have different or equal widths and sizes. Furthermore, said plate has lateral rails that serve to provide structural support to the battery associated with the plate. However, document US2023074724A1 does not disclose a heat exchange base provided with a geometry comprising fluid passage channels with fins arranged symmetrically to each other, projecting from the upper and lower inner walls of each channel, nor does it disclose a specific geometry with a structure for attaching the heat exchange base to the vehicle, the base to the battery module, and a cover for the battery.

[0012] Thus, based on the literature reviewed, no documents were found anticipating or suggesting the teachings of the present invention, so the solution proposed here possesses novelty and inventive step compared to the state of the art. Summary of the Invention

[0013] Thus, the present invention solves the problems of the prior art by means of a modular heat exchange system applied to the battery module base, designed to allow its configuration to be adjusted according to the number of plates associated to form a heat exchange base. This allows the system to be customized according to the battery size, enabling different sets of battery modules to be cooled and / or heated by the present system.

[0014] Furthermore, the heat exchange system of the present invention is provided with fluid circulation channels with optimized geometry to promote the maximization of heat transfer between the fluid and the system.

[0015] Furthermore, the heat exchange system of the present invention is provided with specially adapted connection profiles to promote connection of the system to the battery module(s), of the system to the vehicle, and of the system to a cover structure of the battery module(s).

[0016] In this sense, an objective of the invention is a heat exchange system that optimizes the cooling and / or heating of the battery module, since the heat exchange system itself is used to cool and / or heat the battery modules. Furthermore, the heat exchange between the fluid and the components is maximized through the internal channels of the components equipped with fins, providing greater cooling efficiency.

[0017] In a first object, the present invention presents a heat exchange system applied to a battery module comprising at least one heat exchange base provided with a set of plates associated with each other, wherein the configuration of the heat exchange base is customizable according to the number of plates associated to form the heat exchange base.

[0018] In a second object, the present invention discloses a manufacturing process for a heat exchange system applied to a battery module, comprising a manufacturing step of at least one set of plates by means of a mechanical forming process comprising the steps of: a. manufacturing at least one left side plate and at least one right side plate, and associating at least one left side plate with at least one right side plate; and / or b. manufacturing at least one center plate, at least one left side plate and at least one right side plate, wherein the center plate is associated between at least one left side plate and at least one right side plate.

[0019] Yet another object of the invention is a vehicle comprising at least one battery module, wherein the battery module is associated with a modular heat exchange system applied to the base of the battery module, wherein the modular cooling system comprises at least one heat exchange base provided with a set of interconnected plates, wherein the configuration of the heat exchange base is customizable according to the number of plates associated to form the heat exchange base.

[0020] Another object of the invention is a modular heat exchange system kit and battery module comprising a heat exchange base provided with a set of plates associated with the battery module, wherein the configuration of the heat exchange base is customizable according to the number of plates associated to form the heat exchange base.

[0021] These and other objects of the invention will be immediately appreciated by those skilled in the art and will be described in detail below. Brief Description of the Figures

[0022] The following figures are presented:

[0023] Figure 1 shows an embodiment of the heat exchange system of the present invention, illustrating the central plate (1) and the left (2) and right (3) side plates.

[0024] Figure 2 shows an embodiment of the heat exchange system of the present invention, illustrating the channels (9) of the plates.

[0025] Figure 3 shows an embodiment of the heat exchange system of the present invention, illustrating the fluid-filled plate channels (9).

[0026] Figure 4 shows a cross-sectional view of the plates (1, 2, 3), illustrating the fins present in the channels (9).

[0027] Figure 5 shows a front view of the channels (9), illustrating the fins (9.1) arranged on the inner upper wall (9.2) and on the inner lower wall (9.3) of the heat exchange base.

[0028] Figure 6 shows an embodiment of the closing plate (8) and the highlighted inlet and outlet nozzle (11), which are fixed to the side plates (2, 3), and also illustrates the channels (9) provided with fins (9.1).

[0029] Figure 7 shows one of the possible geometric configurations of the heat exchange base and the arrangement of the battery modules (10), highlighting the modular concept.

[0030] Figure 8 shows one of the possible geometric configurations of the heat exchange base and the arrangement of the battery modules (10), highlighting the modular concept.

[0031] Figure 9 shows one of the possible geometric configurations of the heat exchange base and the arrangement of the battery modules (10), highlighting the modular concept.

[0032] Figure 10 shows one of the possible geometric configurations of the heat exchange base and the arrangement of the battery modules (10), highlighting the modular concept.

[0033] Figure 11 shows a realization of the base association profile (20) of the left (2) and right (3) side plates.

[0034] Figure 12 shows a front view of the plates, illustrating the channels (9), the fin arrangement (9.1) and the different possible configurations of the heat exchange base.

[0035] Figure 13 shows different configurations of heat exchange system sizes and battery module arrangement (10).

[0036] Figure 14 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0037] Figure 15 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0038] Figure 16 shows a perspective view of the left side plate (2).

[0039] Figure 17 shows a front view of the left side plate (2).

[0040] Figure 18 shows an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0041] Figure 19 shows a close-up view of an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0042] Figure 20 shows a close-up view of an embodiment of the battery modules (10) mounted on the heat exchange system of the present invention.

[0043] Figure 21 shows a realization of the heat exchange system, illustrating the connection of the side plates (2, 3) to the central plate (1).

[0044] Figure 22 shows a close-up view of the channels (9) of the plates (1, 2, 3), illustrating the fin arrangement (9.1) and the support flange (9.4).

[0045] Figure 23 shows a perspective view of the heat exchange system of the present invention, illustrating a configuration of three associated plates, being a central plate (1) and two side plates (2, 3). Detailed Description of the Invention

[0046] The present invention describes a heat exchange system applied to a battery module provided with a heat exchange base formed by at least one plate, each plate having a geometry designed to maximize heat transfer between the base and the battery modules, as well as having optimized profiles for fitting and connecting the base to the vehicle, the base to the battery, and the battery to a protective cover.

[0047] Furthermore, the said heat exchange system promotes the concept of modular geometry, which allows configuring the shape / size of the heat exchange base in relation to the size of the battery modules, that is, this concept allows joining plates side by side to form a system that meets different battery module sizes (10) / capacities.

[0048] Thus, the present invention presents a heat exchange system applied to a vehicle battery module comprising at least one heat exchange base provided with a set of interconnected plates.

[0049] For the purposes of the present invention, a "heat exchange base" is defined as a structural component positioned on at least one of the lower, upper, and / or side faces of battery modules, which promotes the dissipation and / or absorption of heat from the battery modules. Thus, the heat exchange base has the function of transferring heat between the battery modules and the base, for cooling and / or heating of the battery modules, maintaining the operating temperature of the modules within safe and efficient limits.

[0050] In one embodiment, the plates that form the present heat exchange base are connected to each other in a modular fashion, allowing different geometric configurations of the heat exchange base to be formed.

[0051] In one embodiment, the configuration of the heat exchange base of the present invention is customizable according to the number of plates associated to form the heat exchange base, that is, the shape / size of the heat exchange base is configurable by changing the number of plates associated with each other, allowing the construction of different heat exchange base geometries.

[0052] Thus, the set of plates of said heat exchange base comprises different geometric configurations, which are formed according to demand, such as, but not limited to, battery size, battery capacity, number of battery modules, etc.

[0053] In one embodiment, the geometric configuration of the heat exchange base comprises a set of plates formed by at least one central plate (1) associated between at least one left side plate (2) and at least one right side plate (3).

[0054] In another embodiment, the geometric configuration of the heat exchange base comprises a set of plates formed by at least one left side plate (2) associated with at least one right side plate (3).

[0055] In another embodiment, the geometric configuration of the heat exchange base comprises a set of plates formed by one or more central plates (1) associated with each other. In another embodiment, the geometric configuration of the heat exchange base comprises a set of plates formed by at least one central plate (1) associated with at least one left side plate (2). In another embodiment, the geometric configuration of the heat exchange base comprises a set of plates formed by at least one central plate (1) associated with at least one right side plate (3).

[0056] Furthermore, the central plate (1) has a defined width based on the size of the battery module to which it is associated. In one embodiment, the width and / or length of the central plate (1) is customized by associating one or more central plates (1) with each other.

[0057] In one embodiment, the left (2) and right (3) side plates comprise symmetrical or asymmetrical profile geometries. In another embodiment, the left (2) and right (3) side plates comprise symmetrical and mirrored profile geometries.

[0058] In any of the geometric configurations of the heat exchange base and embodiments mentioned above, the base plates (1, 2, 3) comprise at least one heat exchange fluid circulation channel (9).

[0059] In one embodiment, the channel (9) comprises a plurality of fins (9.1) projecting from the inner upper wall (9.2) and the inner lower wall (9.3) of the channel (9). For the purposes of the present invention, the fins (9.1) are defined as geometric elements designed to increase the contact area and promote greater turbulence in the flow, intensifying the heat exchange between the fluid and the walls of the channel (9) and increasing the efficiency of heat dissipation or absorption.

[0060] In one embodiment, the fins (9.1) of the inner upper wall (9.2) and the inner lower wall (9.3) are arranged symmetrically to each other and / or with uniform spacing between them. In another embodiment, the fins (9.1) of the inner upper wall (9.2) and the inner lower wall (9.3) are arranged asymmetrically to each other.

[0061] In one embodiment, the fins (9.1) of the inner upper wall (9.2) project perpendicularly from the inner upper wall (9.2) and towards the inner lower wall (9.3), and the fins (9.1) of the inner lower wall (9.3) project perpendicularly from the inner lower wall (9.3) towards the inner upper wall (9.2).

[0062] Additionally, in one embodiment, the heat exchange base comprises a closing plate (8) which is fixed to the central plate (1) and to the left (2) and right (3) side plates.

[0063] In one embodiment, the closing plate (8) comprises at least one inlet and outlet nozzle (11) for inserting or discharging heat exchange fluid into the channels (9) of the plates. In a specific embodiment, the inlet and outlet nozzle (11) is arranged in the closing plates (8) fixed to the left (2) and right (3) side plates. In another embodiment, the inlet and outlet nozzle (11) is arranged in the closing plates (8) fixed to the central plate(s) (1).

[0064] Furthermore, in one embodiment, the heat exchange base comprises at least one support flange (9.4) disposed on the inside of the channels (9), positioned in a recessed position inside the channel (9) relative to the closing plate (8). Said support flanges (9) act to support the walls of the heat exchange base, in addition to contributing to the maximization of heat exchange from the turbulence in the flow of the fluid passing through the channel (9).

[0065] In this way, after the fluid enters through an inlet and outlet nozzle (11), circulates through all the channels (9) of the heat exchange base, the fluid is conducted out of the plate assembly, passing through the inlet and outlet nozzle (11) and returning to a heat exchange management system of the battery, which is positioned externally to the heat exchange system of the present invention.

[0066] Furthermore, in order for the set of plates to form a heat exchange base, the plates (1, 2, 3) comprise association regions between one plate and another and association regions of the heat exchange base to the vehicle, of the heat exchange base to the battery module (10) and of the battery to a protective cover.

[0067] In one embodiment, the plates (1, 2, 3) of the plate assembly comprise at least one plate interlocking profile (21) and / or at least one base association profile (20). The plate interlocking profile (21) is defined as an adapted geometric profile that allows the interlocking and association of one plate (1, 2, 3) with another (1, 2, 3), that is, it is a geometric profile disposed in at least one of the lateral regions of the plates (1, 2, 3) and has the function of joining one plate (1, 2, 3) with another (1, 2, 3). In one embodiment, the plate interlocking profile (21) comprises a straight geometric profile associated between one plate (1, 2, 3) and another (1, 2, 3). The base association profile (20) is defined as a geometric profile that allows the fitting and association of the heat exchange base to the vehicle, the heat exchange base to the battery module (10), and the battery module in a protective cover (22).

[0068] In this sense, in one embodiment, the central plate (1) comprises at least one face provided with geometry adapted to be associated with another central plate (1) and / or with at least one left side plate (2) and / or with at least one right side plate (3). In one embodiment, said face of the central plate (1) comprises at least one plate fitting profile (21) for association with the left side plate (2) and / or the right side plate (3).

[0069] In one embodiment, the left side plate (2) comprises at least two faces, one having a geometry adapted to be associated with at least one center plate (1) and / or at least one right side plate (3), and the other having at least one base association profile (20).

[0070] In one embodiment, the right side plate (3) comprises at least two faces, one having a geometry adapted to be associated with at least one center plate (1) and / or at least one left side plate (2), and the other having at least one base association profile (20).

[0071] In one embodiment, the base mounting profile (20) present on a face of the left side plate (2) and on a face of the right side plate (3) comprises at least one mounting hole to the vehicle (5), at least one mounting hole in the battery module (6) and at least one mounting hole in the battery cover (7).

[0072] The vehicle connection hole (5) is defined as a profile for connecting the heat exchange base of the present invention to the vehicle structure. In one embodiment, the vehicle connection hole (5) is located on a lower face of the left side plate (2) and the right side plate (3), which is the face that comes into contact with the vehicle structure. In one embodiment, said vehicle connection hole (5) comprises a channel with two tabs that fit into a vehicle structure, the tabs being flat, symmetrical and mirrored to each other, and arranged in a manner aligned parallel to the lower face of the left (2) and right (3) side plates.In one embodiment, said vehicle connection hole (5) comprises a channel with two tabs that fit into a vehicle structure by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, connecting the heat exchange base to the vehicle structure.

[0073] The connection hole in the battery module (6) is defined as a profile for connecting the heat exchange base of the present invention to the battery module. In one embodiment, the connection hole in the battery module (6) is disposed on an upper face of the left side plate (2) and the right side plate (3), which is the face that comes into contact with the battery module where the heat exchange is to be performed. In one embodiment, said connection hole to the battery module (6) comprises a geometry mirrored to the geometry of the connection hole to the vehicle (5). In another embodiment, the connection hole to the battery module (6) comprises a geometry asymmetrical to the geometry of the connection hole to the vehicle (5).In one embodiment, the battery module connection hole (6) comprises a channel with two tabs that fit into the lower structure of the battery module (10), the tabs being flat, symmetrical and mirrored to each other, and arranged parallel to the upper face of the left (2) and right (3) side plates. In another embodiment, said connection to the battery module (6) comprises a channel with two tabs that fit into the lower structure of the battery module (10) by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, connecting the heat exchange base to the battery module (10).

[0074] The battery cover mounting hole (7) is defined as a profile for mounting a cover / lid that protects the battery module structure (10), being associated with the left (2) and right (3) side plates. In one embodiment, the battery cover mounting hole (7) is located on a side face of the left side plate (2) and the right side plate (3), said side face being opposite the mounting face to the central plate (1), and is the face that comes into contact with a protective structure (22) of the battery module (10). In another embodiment, the battery cover mounting hole (7) comprises a channel with two tabs that fit into a protective structure (22) of the battery, mounted on the battery module (10). Said tabs comprise symmetrical and mirrored geometries, and are arranged parallel to the side face of the left (2) and right (3) side plates.In one embodiment, the battery cover connection hole (7) comprises a channel with two tabs that fit into the battery protection structure (22) by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, connecting the protection structure (22) to the heat exchange base plates (2, 3).

[0075] Furthermore, in a second object, the present invention discloses a manufacturing process for a modular heat exchange system applied to a battery. Said manufacturing process comprises at least one manufacturing step of at least one heat exchange base comprising a set of interconnected plates, wherein the set of plates comprises a customizable geometric configuration based on the number of plates associated to form the heat exchange base.

[0076] In one embodiment, the process of assembling the plates of the plate assembly comprises a modularized assembly step between one or more plates, which comprises the assembling of plates to form a heat exchange base configuration according to the battery module configuration (10), battery module capacity (10) and / or battery module size (10).

[0077] In one embodiment, after the aforementioned modular assembly stage, the plates of the plate assembly are fixed together by means of a welding process, such as friction welding.

[0078] In one embodiment, the plates in the plate assembly are manufactured entirely through a mechanical forming process. In a specific embodiment, the plates in the plate assembly are manufactured through an extrusion process, which optimizes manufacturing time and reduces machining and welding steps on the parts.

[0079] In one embodiment, the set of plates that forms the heat exchange base is made of metallic material. In a specific embodiment, the set of plates that forms the heat exchange base is made of aluminum. In a specific embodiment, the set of plates that forms the heat exchange base is made of extruded aluminum.

[0080] Furthermore, the set of plates that forms the heat exchange base is manufactured comprising one or two or more plates associated with each other. In one embodiment, the heat exchange base is manufactured comprising a central plate (1). In another embodiment, the heat exchange base is manufactured comprising at least one left side plate (2) associated with at least one right side plate (3). In another embodiment, the heat exchange base is manufactured comprising at least one central plate (1) associated with at least one left side plate (2) and at least one right side plate (3). In one embodiment, the said associations of the plates (1, 2, 3) with each other, to form the heat exchange base, are carried out by means of a friction stir welding (FSW) process.

[0081] For the connection of the plates to each other forming the heat exchange base, and for the connection of the heat exchange base to the vehicle, to the battery module (10) and to the battery in a protective structure (22), the manufacture of the plates (1, 2, 3) comprises a manufacturing step of at least one plate fitting profile (21) and / or at least one base connection profile (20).

[0082] In this sense, in one embodiment, the central plate (1) is manufactured so as to comprise at least one face provided with geometry adapted to be associated with another central plate (1) and / or with at least one left side plate (2) and / or with at least one right side plate (3). For this purpose, in one embodiment, said face of the central plate (1) is manufactured comprising at least one plate fitting profile (21) for association with the left side plate (2) and / or the right side plate (3).

[0083] In one embodiment, the manufacturing step of the left side plate (2) includes the manufacturing of at least two faces, one provided with geometry adapted to be associated with at least one center plate (1) and / or at least one right side plate (3), and another provided with at least one base association profile (20).

[0084] In one embodiment, the manufacturing step of the right side plate (3) includes the manufacturing of at least two faces, one provided with geometry adapted to be associated with at least one center plate (1) and / or at least one left side plate (2), and another provided with at least one base association profile (20).

[0085] Furthermore, in one embodiment, the base mounting profile is manufactured so as to be positioned on one face of the left side plate (2) and on one face of the right side plate (3), and comprises at least one mounting hole to the vehicle (5), at least one mounting hole in the battery module (6) and at least one mounting hole for the battery cover (7).

[0086] In one embodiment, the vehicle connection hole (5) is disposed on a lower face of the left side plate (2) and the right side plate (3), which is the face that comes into contact with the vehicle structure. In one embodiment, said vehicle connection hole (5) is manufactured to comprise a channel with two tabs that fit into a vehicle structure, the tabs being flat, symmetrical and mirrored to each other, and arranged in a parallel alignment to the lower face of the left (2) and right (3) side plates. In one embodiment, said vehicle connection hole (5) comprises a channel with two tabs that fit into a vehicle structure by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, fixing the heat exchange base to the vehicle structure.

[0087] In one embodiment, the connection hole in the battery module (6) is disposed on an upper face of the left side plate (2) and the right side plate (3), which is the face that comes into contact with the battery module where heat exchange is to be performed. In one embodiment, said connection hole to the battery module (6) is manufactured so as to comprise a geometry symmetrical mirrored to the geometry of the connection hole to the vehicle (5). In one embodiment, said connection hole to the battery module (6) is manufactured so as to comprise a geometry asymmetrical to the geometry of the connection hole to the vehicle (5). In one embodiment, the connection hole to the battery module (6) is manufactured so as to comprise a channel with two tabs that fit into the lower structure of the battery module (10), the tabs being flat, symmetrical and mirrored to each other, and disposed parallel to the upper face of the left (2) and right (3) side plates.In one embodiment, the hole for attaching to the battery module (6) comprises a channel with two tabs that fit into the lower structure of the battery module (10) by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, fixing the heat exchange base to the battery module (10).

[0088] In one embodiment, the battery cover mounting hole (7) is disposed on a side face of the left side plate (2) and the right side plate (3), said side face being opposite the mounting face to the center plate (1), and is the face that comes into contact with a battery protection structure (22). In another embodiment, the battery cover mounting hole (7) is manufactured to comprise a channel with two tabs that fit into a battery protection structure, mounted on the battery module. Said tabs comprise symmetrical and mirrored geometries, and are disposed parallel to the side face of the left (2) and right (3) side plates.In one embodiment, the battery cover connection hole (7) comprises a channel with two tabs that fit into the battery protection structure (22) by means of at least one non-permanent fastening means, such as, but not limited to, screws, nuts, rivets, connecting the protection structure (22) to the heat exchange base plates (2, 3).

[0089] Furthermore, the central plate (1) and the left (2) and right (3) side plates are manufactured comprising at least one internal channel (9) for the circulation of heat exchange fluid.

[0090] In one embodiment, the channel (9) is provided with a plurality of fins (9.1) projecting from the inner upper wall (9.2) and the inner lower wall (9.3) of the channel (9). In one embodiment, the channel (9) and said plurality of fins (9.1) of the inner upper wall (9.2) and the inner lower wall (9.3) are manufactured by means of a mechanical forming process. In a specific embodiment, the channel (9) and said plurality of fins (9.1) of the inner upper wall (9.2) and the inner lower wall (9.3) are manufactured by means of an extrusion process.

[0091] In one embodiment, the fins (9.1) of the upper inner wall (9.2) and of the lower inner wall (9.3) are manufactured so that they are arranged symmetrically to each other and with uniform spacing between them. In another embodiment, the fins (9.1) of the upper inner wall (9.2) and of the lower inner wall (9.3) are manufactured so that they are arranged asymmetrically to each other and with non-uniform spacing between them.

[0092] In one embodiment, the fins (9.1) of the inner upper wall (9.2) are manufactured so as to project perpendicularly from the inner upper wall (9.2) and towards the inner lower wall (9.3), and the fins (9.1) of the inner lower wall (9.3) are manufactured so as to project perpendicularly from the inner lower wall (9.3) towards the inner upper wall (9.2).

[0093] Additionally, the manufacturing process of the heat exchanger base comprises the fabrication of a closing plate (8), which is fixed to the central plate (1) and to the left (2) and right (3) side plates. In one embodiment, the closing plate (8) is welded to the plates (1, 2, 3).

[0094] In one embodiment, the closing plate (8) is manufactured to comprise at least one inlet and outlet nozzle (11) for insertion or outlet of heat exchange fluid into the channels (9) of the plates. In a specific embodiment, the inlet and outlet nozzle (11) is disposed in the closing plates (8) fixed to the left (2) and right (3) side plates. In another embodiment, the inlet and outlet nozzle (11) is disposed in the closing plates (8) fixed to the central plate(s) (1).

[0095] Furthermore, the channel (9) of the plates (1, 2, 3) is manufactured comprising at least one support flange (9.4) disposed in the inner part of the channel (9) and positioned in a recess inward from the closing plates (8). In one embodiment, said support flanges (9.4) are manufactured by means of a machining process.

[0096] Furthermore, the manufacturing process of the heat exchange base comprises a step of inserting a fluid through the inlet and outlet nozzle (11), which circulates through all the channels (9) of the heat exchange base, and is conducted to the outside of the plate assembly, passing through the inlet and outlet nozzle (11) and returning to a heat exchange management system of the battery, which is positioned externally and connected to the heat exchange system of the present invention. Additionally, the fluid can be inserted through the inlet and outlet nozzle (11) to travel through the channels (9) and check for any leaks and validate the product.

[0097] Yet another object of the invention is a vehicle comprising at least one battery module (10), wherein the battery module (10) is associated with a modular heat exchange system applied to the base of the battery module (10), wherein the modular cooling system comprises at least one heat exchange base provided with a set of plates connected to each other, wherein the configuration of the heat exchange base is customizable according to the number of plates connected to form the heat exchange base.

[0098] In this way, the modular heat exchange system of the present invention allows optimizing the cooling and / or heating of a vehicle's batteries, providing the following advantages: a lighter and more resistant system, since the plates and the set of plates are manufactured by a metal forming process; greater energy efficiency, since the set of plates is equipped with channels (9) with a plurality of fins (9.1) and support tabs (9.4) that maximize heat exchange between the fluid and the plates; and modularization of the number of plates (1, 2, 3) in the set of plates associated with each other, according to the size / capacity / geometric configuration of the vehicle's battery modules (10).

[0099] In a fourth object, the present invention provides a modular heat exchange system kit and battery module comprising a heat exchange base provided with a set of plates associated with the battery module (10), wherein the configuration of the heat exchange base is customizable according to the number of plates associated to form the heat exchange base.

[0100] In one embodiment, the heat exchange base is associated under the battery module (10) and / or on the battery module (10) and / or on the sides of the battery module (10).

[0101] The examples shown here are intended only to illustrate one of the numerous ways of carrying out the invention, without, however, limiting its scope. Example 1 - Heat Exchange Base for Vehicle Batteries

[0102] In this example, a base for vehicle batteries was developed possessing a heat exchange system for cooling and / or heating battery modules, wherein the developed base was designed to be associated under the battery modules (10). In this sense, the developed concept allows the base itself to be used as a cooling / heating system for the battery modules (10).

[0103] In this example, the heat exchange base is formed by at least 3 plates, being a central plate (1), and two left (2) and right (3) side plates, where the central plate (1) is formed by one or more central plates (1) and is associated between the left (2) and right (3) side plates. The base is as illustrated in figures 1, 21, 23 and 24.

[0104] Furthermore, the plates (1, 2, 3) of the developed heat exchange base are manufactured entirely through an aluminum extrusion process. This manufacturing method provides several procedural and product advantages, such as reduced manufacturing time, since the extrusion process allows for the generation of parts with a more precise finish, reducing the number of machining and welding steps.

[0105] Furthermore, manufacturing the plates (1, 2, 3) in aluminum provides lighter parts, reducing the total weight of the system as a whole and consequently reducing the weight of the vehicle's battery pack (10).

[0106] The concept developed in the present invention is the possibility of customizing the geometric configuration of the heat exchange base according to the size, capacity and / or geometry of the battery modules (10) to be associated with the base. This customization allows changing the geometry, width and / or length of the heat exchange base by associating one or more central plates (1) together, i.e., adding or removing associated central plates (1). Thus, the heat exchange base allows the modularization of plates and provides different possibilities for geometric configurations of the heat exchange base, being able to meet various types of battery pack configurations.

[0107] After defining the customized geometric configuration of the heat exchange base, the two left (2) and right (3) side plates are fixed, one on each side face of the central plate (1), by means of friction stir welding (FSW), allowing greater precision in fixing the parts and reducing deformations and failure regions in the welding. Figures 7, 8, 9, 10 and 13 show different length configurations of the heat exchange base and arrangement of modules (10) on top of the base.

[0108] For the connection of the plates (1, 2, 3) to each other forming the heat exchange base, and for the connection of the base to the vehicle, to the battery module (10) and of the battery to a protective structure, the central plate (1) has lateral faces provided with a plate fitting profile (21) and the left (2) and right (3) lateral plates have a lateral face provided with a base connection profile (20). The plate fitting profiles (21) and the base connection profiles (20) are manufactured in the aluminum extrusion process for the manufacture of the plates (1, 2, 3).

[0109] The plate fitting profile (21) of the center plate (1) was developed to connect one center plate to another center plate (1) and / or connect to a left side plate (2) and a right side plate (3).

[0110] The left (2) and right (3) side plates have a face with geometry developed to match the center plate (1) and a face with a base matching profile (20) with geometry specially developed to match the base to the vehicle, to the battery module (10) and to match the battery in a protective structure (22).

[0111] As illustrated in Figure 11, the mounting profile has a vehicle mounting hole (5) for attaching the base to the vehicle, a battery module mounting hole (6) for attaching the battery modules (10) to the base, and a battery cover mounting hole (7) for attaching the protective structure to the base. These attachments are made using screws that pass through the holes (5, 6, 7). Figures 14, 15, 18, 19 and 20 show the base mounted to the battery modules (10).

[0112] The vehicle connection hole (5) is located on the face of the base that comes into contact with the vehicle structure. Said vehicle connection hole (5) is formed by a channel with two tabs that fit into a vehicle structure, the tabs being flat, symmetrical and mirrored to each other, and arranged in a parallel alignment to the lower face of the left (2) and right (3) side plates.

[0113] The connection hole in the battery module (6) is located on the face of the base that comes into contact with the battery module (10) where heat exchange is to be performed. Said connection hole to the battery module (6) has a geometry symmetrical to the geometry of the connection hole to the vehicle (5) and has the shape of a channel with two tabs that fit into the lower structure of the battery module (10), the tabs being flat, symmetrical and mirrored to each other, and arranged parallel to the upper face of the left (2) and right (3) side plates.

[0114] Furthermore, the battery cover mounting hole (7) is located on the plates (2, 3) on a side face opposite the mounting face to the central plate (1), which is the face that comes into contact with a battery protection structure. Thus, the battery cover mounting hole (7) is formed by a channel with two tabs that fit into a battery protection structure, mounted on the battery module (10). Said tabs comprise symmetrical and mirrored geometries, and are arranged parallel to the side face of the left (2) and right (3) side plates.

[0115] Furthermore, each plate (1, 2, 3) has internal channels (9) for the passage of the heat exchange fluid, as illustrated in figures 2 and 3, where figure 2 illustrates the empty channels (9) and figure 3 illustrates the channels (9) filled with fluid. The channels (9) have fins (9.1) that project from the upper inner wall (9.2) and the lower inner wall (9.2) of the channels (9), so that these fins promote greater heat exchange between the fluid and the plates by maximizing the contact area of ​​the fluid with the fins (9.1) of the plates (figure 12), in addition to greater energy efficiency gain. Said fins (9.1) are manufactured by means of an aluminum extrusion process that forms the geometry of the plates (1, 2, 3).

[0116] Furthermore, figures 4, 5 and 6 highlight the channels (9) equipped with fins (9.1) through which the heat exchange fluid passes. As illustrated, the fins (9.1) of the upper inner wall (9.2) and the lower inner wall (9.3) are manufactured so that they are arranged symmetrically to each other and with uniform spacing between them.

[0117] Furthermore, the fins (9.1) of the inner upper wall (9.2) are manufactured so as to project perpendicularly from the inner upper wall (9.2) and towards the inner lower wall (9.3), and the fins (9.1) of the inner lower wall (9.3) are manufactured so as to project perpendicularly from the inner lower wall (9.3) towards the inner upper wall (9.2). Thus, the fins (9.1) of the upper wall (9.2) and the lower wall (9.3) are arranged symmetrically and aligned with each other within the channel (9).

[0118] The heat exchange base also comprises support tabs (9.4) arranged on the inside of the channels (9), as illustrated in figures 4, 16 and 22, where they are positioned in a recessed position inside the channel (9) relative to the closing plate (8). Said support tabs (9) serve to support the walls of the heat exchange base, in addition to contributing to the maximization of heat exchange from the turbulence in the flow of the fluid passing through the channel (9).

[0119] Furthermore, the curves for the passage and direction of fluid flow are formed by the geometric configuration of the channels themselves (9).

[0120] For closing the channels (9), the developed base has closing plates (8) fixed to the plates (1, 2, 3) by welding, being manufactured by means of an aluminum extrusion process. The closing plates (8) of the left (2) and right (3) side plates have an inlet and outlet nozzle (11) for inserting or discharging the heat exchange fluid into the channels (9) of the plates (2, 3). Figure 6 illustrates the closing plate (8) in detail.

[0121] In this way, the aluminum extruded plates (1, 2, 3) and closing plates (8) allow for the optimized manufacturing of the internal channels (9) of the plates (1, 2, 3), reducing the need for machining and milling steps. This provides a time saving in the plate manufacturing process, as well as a reduction in welding steps in the manufacturing process. Furthermore, manufacturing in aluminum provides a reduction in the weight of the plates, when compared to plates made of other metal alloys in the prior art.

[0122] Figure 16 shows a perspective view of the left side plate (2), illustrating the association profile and channels (9).

[0123] Figure 17 shows a front view of the left side plate (2).

[0124] Figure 22 shows a view highlighting channel (9) of the plate.

[0125] Those skilled in the art will appreciate the knowledge presented here and will be able to reproduce the invention in the forms presented and in other variants and alternatives, covered by the scope of the following claims.

Claims

Claims 1. A heat exchange system applied to a battery module, characterized by comprising at least one heat exchange base provided with a set of interconnected plates, wherein the configuration of the heat exchange base is customizable according to the number of plates associated to form the heat exchange base.

2. System according to claim 1, characterized in that the set of plates comprises: - at least one left side panel (2) associated with at least one right side panel (3); and / or - at least one center plate (1) associated between at least one left side plate (2) and at least one right side plate (3).

3. System according to claim 1, characterized in that the plates of the plate assembly comprise at least one plate fitting profile (21) and / or at least one base association profile (20).

4. System, according to any one of claims 1 to 3, characterized in that the central plate (1) comprises at least one plate fitting profile (21) for association with the left side plate (2) and / or the right side plate (3).

5. System, according to any one of claims 1 to 4, characterized in that the left side plate (2) and the right side plate (3) comprise at least one base association profile (20).

6. System according to claim 1, characterized in that each plate of the plate assembly comprises at least one heat exchange fluid circulation channel (9), wherein the channel (9) comprises a plurality of fins (9.1) projecting from the inner upper wall (9.2) and the inner lower wall (9.3) of the channel (9).

7. Manufacturing process for a modular heat exchange system applied to a battery, characterized by comprising at least one manufacturing step of at least one heat exchange base comprising a set of interconnected plates, wherein the set of plates comprises a customizable geometric configuration based on the number of plates associated to form the heat exchange base.

8. Manufacturing process according to claim 7, characterized by comprising a manufacturing step of at least one set of plates by means of a mechanical forming process comprising the steps of: a. manufacture of at least one left side panel (2) and at least one right side panel (3), and joining at least one left side panel (2) to at least one right side panel (3); and / or b. manufacture of at least one center plate (1), at least one left side plate (2) and at least one right side plate (3), wherein the center plate (1) is joined between at least one left side plate (2) and at least one right side plate (3).

9. Manufacturing process, according to any one of claims 7 to 8, characterized in that the manufacturing step of the plates of the plate assembly comprises a manufacturing step of at least one plate fitting profile (21) and / or at least one base association profile (20).

10. Manufacturing process, according to any one of claims 7 to 9, characterized in that the central plate (1) and the left (2) and right (3) side plates are manufactured comprising at least one internal channel (9) for circulation of heat exchange fluid, wherein the channel (9) is provided with a plurality of fins (9.1) projecting from the inner upper wall (9.2) and the inner lower wall (9.3) of the channel (9).

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