Cooling module and method for producing a cooling module

• US 9,306,224 B2
• Filed: 08/30/2011
• Issued: 04/05/2016
• Est. Priority Date: 09/02/2010
• Status: Active Grant

• Current Assignee: Akasol AG (BorgWarner Incorporated)
• Original Assignee: Akasol Engineering GmbH
• Inventors: Eberleh, Bjrn, Von Borck, Felix
• Primary Examiner(s): Ruddock, Ula C
• Assistant Examiner(s): PARSONS, THOMAS H
• Application Number:
  US13/820,499
• Publication Number:
  US 20130266838A1
• Time in Patent Office: 1,680 Days
• US Class Current: 1/1
• CPC Class Codes: B21D 53/06 of metal tubes
• CPC Class Codes: F28D 1/0476 the conduits having a non-circular cross-section
• CPC Class Codes: F28D 2021/0028 for cooling heat generating elements, e.g. for cooling electronic components or electric devices for cooling semiconductors H01L23/34, for cooling electric apparatus H05K7/20
• CPC Class Codes: F28F 19/06 of metal
• CPC Class Codes: F28F 3/12 Elements constructed in the shape of a hollow panel, e.g. with channels F28D1/02, F28D1/03 take precedence
• CPC Class Codes: F28F 9/0273 with multiple holes
• CPC Class Codes: F28F 9/26 Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators connecting different sections in water heaters F24H9/14 , connecting headers with inlet or outlet fittings F28F9/0246
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6555 arranged between the cells
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 6/5038 Heating or cooling of cells or batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/49391 Tube making or reforming

Abstract

The invention relates to method for the manufacture of a cooling module in the form of a body having an inner space for the reception of battery cells, wherein the body has one or more cooling passages extending in parallel to one another between an inlet region and an outlet region and is formed at least partly from a length or from a plurality of lengths of a hollow section.

Claims

1. A method for the manufacture of a cooling module in the form of a body having an inner space for the reception of battery cells, wherein the body has one or more cooling passages extending in parallel to one another between an inlet region and an outlet region, wherein the body of the cooling module is formed approximately in the shape of a parallelepiped having at least first and second oppositely disposed sides and a third side, the cooling module having a liquid cooling at at least said first, second and third sides, which are consecutive sides, the body being formed at least partly from at least one length of a hollow section by one of the following steps:

bending the at least one length of the hollow section at at least two positions; and

connecting consecutive lengths of the hollow section to one another in a fluid conducting manner;

to form at least two typically at least substantially rectangular corners, wherein the cooling module is subsequently provided with sheet metal connection plates which are attached at at least the first and the second oppositely disposed sides in a heat conducting manner and which form compartments which are dimensioned for the reception of the battery cells, wherein the sheet metal connection plates and the cooling passages lie in a common plane.

2. A method in accordance with claim 1, wherein the at least one length of hollow section has first and second oppositely disposed longitudinal sides, wherein a plurality of lengths of hollow sections are provided which are connected to one another at adjacent longitudinal sides.

3. A method in accordance with claim 1, wherein, on the use of a plurality of lengths of hollow sections, these are bent prior to or after their connection.

4. A method in accordance with claim 1, wherein the sheet metal connection plates are inserted into guide grooves extending in the longitudinal direction of the length of hollow section.

5. A method in accordance with claim 1, wherein a distributor is provided in the inlet region, the distributor being arranged substantially perpendicular to the individual cooling passages and which distributes a coolant into the individual cooling passages during operation and wherein a collector is provided in the outlet region, and wherein the collector is arranged approximately perpendicular to the cooling passages and receives and guides the coolant from the individual cooling passages to an outlet during operation.

6. A method in accordance with claim 5, wherein the distributor and the collector are attached to the at least one length of hollow section.

7. A method in accordance with claim 1, wherein the length of hollow section is post-treated by at least one of an anodic treatment method, a coating method and powder coating and is thereby electrically insulated and protected.

8. A cooling module in the form of a body having an inner space for the reception of battery cells, wherein the body has one or more cooling passages extending in parallel to one another between an inlet region and an outlet region, wherein the body of the cooling module is approximately of the shape of a parallelepiped having at least first and second oppositely disposed sides and a third side and the body having a liquid cooling at at least said first, second and third sides, which are consecutive sides, the body having been formed at least partly from at least one length of a hollow section by one of the following steps:

bending the at least one length of the hollow section at at least two positions; and

connecting consecutive lengths of the hollow section to one another at abutting ends in a fluid conducting manner;

thereby forming at least two typically at least substantially rectangular corners, the cooling module further having sheet metal connection plates which are attached at at least said first and second oppositely disposed sides in a heat conducting manner and forming compartments which compartments are dimensioned for the reception of battery cells, wherein the sheet metal connection plates and the cooling passages lie in a common plane.

9. A cooling module in accordance with claim 8, wherein the at least one length of hollow section has first and second oppositely disposed longitudinal sides, wherein a plurality of lengths of hollow sections are provided which are connected to one another at adjacent longitudinal sides.

10. A cooling module in accordance with claim 9, wherein each length of hollow section has at least one coolant guiding passage disposed between the first and second longitudinal sides, there being a groove arranged at the first longitudinal side, and a tongue at the second longitudinal side, wherein the groove and the tongue lie in a common plane.

11. A cooling module in accordance with claim 10, wherein the length of hollow section has a guide groove which is laterally arranged with regard to the mentioned plane.

12. A cooling module in accordance with claim 10, wherein the length of hollow section has a second passage which is configured to manufacture a connection between the length of hollow section and a component attachable thereto.

13. A cooling module in accordance with claim 10, wherein the length of hollow section has first and second hollow fluid passages and a wall section formed therebetween.

14. A cooling module in accordance with claim 8, wherein the sheet metal connection plates are inserted into guide grooves extending in the longitudinal direction of the length of hollow section.

15. A cooling module in accordance with claim 8, wherein a distributor is provided in the inlet region, with the distributor being arranged approximately perpendicular to the individual cooling passages and distributing a coolant into the individual cooling passages during operation;

and wherein a collector is provided in the outlet region, with the collector being arranged approximately perpendicular to the cooling passages and receiving and guiding the coolant from the individual cooling passages to an outlet during operation.

16. A cooling module in accordance with claim 8, wherein the cooling module is electrically insulated.

17. A cooling module in accordance with claim 8, wherein the cooling module is stabilized by a support section at a front end of the cooling module.