DE102022211531A1 - Cooler and method of making a cooler - Google Patents

Abstract

A cooler (12) has at least one flat tube (16) with a plurality of flow channels through which flow can flow in a U-shape, the flat tube (16) integrally having a seal (32) between differently directed flow paths, which are via inlet and/or Outflow of the flat tube (16) extends out from the flat tube (16).In a method for producing a cooler (12), a flat tube (16) is extruded and punched, a tank (18) is punched from sheet metal and subsequently folded, and flat tube ( 16) and tank (18) are soldered together.

Description

Technical area

The invention relates to a cooler, in particular for battery cells, and a method for producing a cooler.

As electromobility grows in importance, it is necessary to provide coolers for battery cells that supply electrical energy to the electric drives of vehicles such as cars.

State of the art

In particular for cylindrical battery cells, for example, it is from US 2008 311468 A1 known to use numerous flat tubes, which can be corrugated, to cool numerous cylindrical battery cells. The battery cells are typically accommodated in the wave troughs. Similar orders come from the CN205752451 U and US 10020550 B2 out.

According to the WO 2021/123550 A1 a substantially plate-shaped cooler is flowed through in a U-shape, and according to the CN 206505995 U a flat tube is flowed through in opposite directions in separate halves.

Presentation of the invention

Against this background, the invention is based on the object of providing an efficiently producible and leak-free cooler and a manufacturing method for this.

This problem is solved on the one hand by the cooler described in claim 1.

As a result, it has at least one flat tube with several flow channels through which flow can flow in a U-shape. Furthermore, the flat tube is typically connected to a tank and has a one-piece seal between differently directed flow paths, which preferably interacts with solder for the sealing effect and extends beyond the inflow and/or outflow of the flat tube from the flat tube. The flow through the flat tube is therefore essentially U-shaped. For this purpose, a suitable deflection for the flow from one half of the flat tube to the other is provided at the end opposite the tank.

The flat tube and the typically multiple flow channels provided therein extend essentially parallel and have a length measured in the direction of flow that is significantly larger, for example at least three times as large, as a width measured perpendicular thereto. In a section perpendicular to the direction of flow, width is understood to mean that surface of the flat tube which in turn is significantly larger than the narrow sides, for example at least five times as large.

On the one hand, the cooler can be produced efficiently in that the flat tube, including the section referred to above and below as the seal, can be produced from an aluminum alloy or aluminum by extrusion and subsequent punching in the area of the seal. Instead of extrusion, roll forming, in other words folding, with subsequent welding or soldering can be used. Furthermore, the tank can be manufactured, for example by punching and bending and typically from sheet metal, so that it does not need to be reworked. The seal designed as a one-piece extension or “nose” ensures the necessary seal between the two flow paths, which can therefore also be formed in one piece on the flat tube in an efficient manner during the extrusion process. The flat tube and the tank can be connected efficiently by soldering. The seal can be arranged in the tank in a suitable manner.

Further preferred embodiments are described in the further claims.

As mentioned, the cooler preferably has a collector at the end opposite the tank. This allows the flow to be diverted in a U-shape. The collector can efficiently consist of aluminum or an aluminum alloy and can preferably be punched and/or bent and essentially surrounds an end region of the flat tube.

A particularly reliable seal and arrangement relationship between the components mentioned arise when the tank accommodates the seal between the differently directed flow paths.

For the supply and removal of coolant, the tank is provided with at least two fluid connections, each of which preferably has at least one sealing element. The fluid connections can be essentially tubular, with one end region having a smaller outside and inside diameter. The outer diameter can in particular be designed such that the fluid connection, preferably with one or more sealing elements, for example O-rings in between, in the end region of an identically shaped fluid connection of an adjacent arrangement of flat tube, tank and fluid connections, can be inserted into the end region with a larger inner diameter. This allows an arrangement of numerous flat tubes arranged in parallel to be formed in order to efficiently cool numerous battery cells. The fluid connections can preferably be in one piece, so that they form a “male connector” in the form of the end with a smaller outside diameter and a “female connector” in the form of the end with a larger outside diameter. As referred to below 2 Described in more detail, they can be combined and soldered radially and axially to the tank, so that there is advantageously no double fit.

Thus, the preferably provided sealing element seals reliably in the inserted state between the end with a smaller diameter and the end with a larger diameter.

The fluid connections preferably each have a slot, which serves for the fluid connection between the fluid connections and the flat tube and is advantageously easy to produce.

At least one slot that is elongated and extends over approximately a quarter of the circumference of a circular cylindrical fluid connection has proven to be advantageous.

Furthermore, it is preferred that the width of at least one slot corresponds approximately to the height of the flat tube. The height, which could also be referred to as thickness, is considered perpendicular to the direction of flow in the flat tubes and perpendicular to the width of the flat tubes.

The cooler according to the invention is particularly suitable for cylindrical battery cells if the flat tubes are wave-shaped in a direction perpendicular to the flow direction and perpendicular to the wider side. In other words, the waveform can be seen when looking towards one of the two narrow sides. However, the wave shape can also be omitted, or in the direction of view mentioned, the flat tube can have a different shape, which can be adapted, for example, to prismatic cells to be cooled.

The assembly can be further simplified, and the positional relationships between the components mentioned are particularly well defined if at least one flat tube and/or at least one fluid connection and/or the tank has a stop. In the case of the fluid connections, they can be designed, for example, as an externally circumferential bead, which essentially forms a rib or a web. In the case of the flat tube, the stop can be formed by the end of the seal.

A particularly reliable separation of the two flow directions from one another is achieved when the tank and seal are soldered together.

For ease of manufacture and functionality at the same time, it is preferred that the seal is essentially rectangular in a top view.

The seal can be produced particularly reliably if the seal has a substantially uniform thickness. The thickness is considered perpendicular to the direction of flow in the flat tubes and perpendicular to the width of the flat tubes.

For example, a seal with a substantially uniform thickness can work particularly effectively with regard to tightness with a tank that has two halves folded parallel to one another and connected by an extension.

As already indicated above, several coolers with flat tubes can be combined with one another to form a cooling device, in particular in such a way that the flat tubes are rotated by 180° with respect to adjacent flat tubes. As a result, wave troughs lie opposite one another, in which battery cells, in particular cylindrical battery cells, can be accommodated.

The method according to the invention is described in claim 19 and has already been explained above. It should also be mentioned that all of the features specified above and below in connection with the cooler are applicable to the method according to the invention and vice versa.

Brief description of the drawings

• 1 eine Anordnung mehrerer erfindungsgemäßer Kühler mit zu kühlenden Batteriezellen;
• 2 einen wesentlichen Abschnitt des erfindungsgemäßen Kühlers in einer perspektivischen Ansicht;
• 3 das Ende des Flachrohrs in einer perspektivischen Ansicht;
• 4 und 5 das Flachrohr und den Tank in einer perspektivischen (Schnitt-)Ansicht;
• 6 den Endabschnitt des Flachrohrs in einer perspektivischen Ansicht;
• 7 das dem Tank gegenüberliegende Ende eines Flachrohrs in einer perspektivischen Ansicht; und
• 8 bis 10 das vorangehend genannte Ende in unterschiedlichen perspektivischen Schnittansichten.

Preferred exemplary embodiments of the invention are explained in more detail below with reference to the drawings. Show it:

• 1 an arrangement of several coolers according to the invention with battery cells to be cooled;
• 2 an essential section of the cooler according to the invention in a perspective view;
• 3 the end of the flat tube in a perspective view;
• 4 and 5 the flat pipe and the tank in a perspective (sectional) view;
• 6 the end section of the flat tube in a perspective view;
• 7 the end of a flat tube opposite the tank in a perspective view; and
• 8th until 10 the aforementioned end in different perspective sectional views.

Detailed description of preferred embodiments of the invention

1 shows the basic structure of a cooling device 10 with several coolers 12 according to the invention, which in the case shown are wave-shaped when viewed in the direction of the narrow side (in the figure on the top and bottom). Here, adjacent coolers 12 are rotated by 180° with respect to each other, so that wave troughs lie opposite each other, in which, for example, cylindrical battery cells 14 can be accommodated. The figure shows a flat tube 16 for each cooler 12, the upper and lower halves of which can be flowed through in opposite directions. This essentially results in a U-shaped flow starting from an inlet, which will be explained in more detail below and is located in the 1 on the right, for example at the bottom, to the left in the figure to a deflection at the end, and back to the right to an outlet, which is for example at the top of the figure. As can be seen, all inlets and outlets are connected to one another and are aligned with one another, so that all coolers, in particular their flat tubes 16, are arranged essentially parallel and can be supplied with coolant, for example, through the inlet that can be seen on the far left in the figure, and this can be removed again through the outlet that can be seen on the far left and at the top of the figure.

This in 2 The flat tube 16 shown has numerous flow channels extending in the flow direction indicated by arrows and is therefore flowed through in a U-shape overall, as can be seen by the arrows. As will be described in more detail below, the flat tube 16 is connected to a tank 18 with an integrated seal 32. The tank 18 essentially has a cross section with parallel long sides and essentially semi-cylindrical ends for receiving the flat tube 16 including the seal 32. Furthermore, it is soldered to preferably circular cylindrical fluid connections 24, which have an end with a larger diameter 26 and an end with a smaller diameter 28. Here, the end with a smaller diameter 28 is dimensioned such that it can be inserted into the end with a larger diameter 26 of an adjacent cooler with a sealing element (not shown) in between, so that overall the exemplary in 1 shown arrangement arises. In the case shown, the end with a smaller diameter 28 has two circumferential grooves 30, into each of which, for example, a sealing element in the form of an O-ring 46 can be inserted. The fluid connections 24 can be soldered to the tank 18 as mentioned. The fluid connections are essentially tubular and extend perpendicular to the direction of flow and perpendicular to the broad side of the flat tubes 16, which according to 1 and 2 runs from bottom left to top right.

Out of 2 In addition, it follows that in the area of the tank 18, essentially in the area of the seal 32, there is no flow connection between the halves of the flat tube 16. In other words, the in 2 The fluid connection shown above is only in fluid connection with the upper half of the flat tube, and the lower one with the lower half.

In the case shown, the fluid connections 24 each have a circumferential stop 54, which defines the position of the respective fluid connection 24 with respect to the tank 18. In the area of the stop 54, the respective fluid connection 24 is soldered to the tank 18 in the axial direction in the area 56. Here, the surface of the tank 18 lies essentially flat against that of the stop 54. On the side opposite the stop 54, the opening provided for the fluid connection 24 is essentially delimited by a collar 58, which in turn lies flat against the cylindrical surface of the fluid connection 24, so that a soldered connection is formed here in the radial direction.

In 2 It can also be seen that the tank is on its sides, according to the orientation in 2 Upper and lower ends are formed by soldering flat extensions. On the side facing the flat tube 16, the connection of the two halves of the tank can be made according to the orientation in 2 in front of and behind the flat tube 16 through suitable tabs 52.

Out of 2 It also follows that the fluid connections 24 each have a slot 34, which serves for the fluid connection between the fluid connections 24 and the flat tube 16.

From the sectional view according to 2 perpendicular to the flow direction in the fluid connections 24 and 3 and 4 It can be seen that the flat tube 16 has a one-piece extension, which is also referred to as a “nose”. can, and find out about the inflow and outflow of the flat pipe, which is based on the in 3 open, separated flow channels can be seen. This extension forms the seal 32 according to the invention and is essentially along the width of the flat tube 16, according to the orientation in 2 until 4 along the height, centrally formed and in the case shown corresponds approximately to the width of three to four flow channels. When assembled, the seal is 32, as in 2 and 4 recognizable, introduced into the tank 18. This also applies to the frontmost millimeters in the area of the flow channels. Flat tube 16 and tank 18 can be soldered together. For this purpose, the tank 18 can be provided with suitable solder.

In the area of the seal 32 and significantly wider, the tank 18 also has an extension 60, which connects the two halves of the tank 18 already mentioned above, according to the figures in front of and behind the flat tube 16, and around which the two halves are bent towards each other can. The extension, which acts as a kind of hinge, can also be narrower, and there can be several such narrower extensions.

In the section view of 5 It can also be seen that flat tube 16 and tank 18 can be designed to be essentially congruent with regard to their outer and inner contours, and can therefore be soldered together flatly.

This in 6 The end of the seal 32 shown in detail corresponds, viewed in cross section, essentially to the shape of the tank 18 in the area of its extension 60.
As in supplementary 2 and 4 can be seen, the tank 18 completely accommodates the seal 32. This ensures a seal between the two halves of the flat tube 16.

In the remaining figures, the collector 40 is shown at the end opposite the tank 18. In the case shown, this is punched from a sheet, for example from aluminum or an aluminum alloy, and bent around the flat tube in such a way that the flow received by one half of the flat tube 16 is deflected essentially by 180 ° or a total of U-shaped and into the other Half of the flat tube 16 is guided. As can be seen in the figures, an upper and a lower half of the collector 40 can be connected by one or more webs 42, which can also be narrower than shown, and fastened to one another by means of side tabs 44. The halves described can also be soldered to one another and to the flat tube 16. This applies, for example, to the 8th and 9 flat areas to be recognized 48.

Any features described herein may be combined with any features described in Applications Nos. 248565 and 248459, also filed today, so long as they do not conflict with each other.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 2008311468 A1 [0003]
• CN 205752451 [0003]
• US 10020550 B2 [0003]
• WO 2021123550 A1 [0004]
• CN 206505995 U [0004]

Claims (21)

Cooler (12) with at least one flat tube (16) with a plurality of flow channels through which flow can flow in a U-shape, the flat tube (16) integrally having a seal (32) between differently directed flow paths, which are located via the inflow and/or outflow of the Flat tube (16) extends out from the flat tube (16). Cooler (12). Claim 1 , characterized in that at least one flat tube (16) consists of aluminum or an aluminum alloy and is preferably extruded and punched, and / or at least one tank (18) consists of sheet metal. Cooler (12) according to one of the preceding claims, characterized in that at least one collector (40), preferably made of an aluminum or an aluminum alloy sheet, is further arranged at an end opposite to the seal (32). Cooler (12) according to one of the preceding claims, characterized in that the tank (18) accommodates the seal (32). Cooler (12) according to one of the preceding claims, characterized in that the tank (18) is provided with at least two fluid connections (24), which are preferably each provided with at least one sealing element (46). Cooler (12). Claim 5 , characterized in that each fluid connection (24) has an end with a larger diameter (26) and an end with a smaller diameter (28), the end with a smaller diameter (28) being dimensioned such that it may be connected to the sealing element ( 46) can be inserted between them into an end with a larger diameter (26) of an adjacent cooler. Cooler (12). Claim 5 or 6 , characterized in that the sealing element (46) seals in the inserted state between the end with a smaller diameter (28) and the end with a larger diameter (26). Cooler (12). Claim 5 , 6 or 7 , characterized in that at least one fluid connection (24) is soldered radially and axially to the tank (18). Radiator (12) according to one of the Claims 5 until 8th , characterized in that the fluid connections (24) each have a slot (34) which serves for the fluid connection between the fluid connections (24) and the flat tube (16). Cooler (12). Claim 9 , characterized in that at least one slot (34) is elongated and extends over approximately a quarter of the circumference of a circular cylindrical fluid connection (24). Cooler (12). Claim 9 or 10 , characterized in that the width of at least one slot (34) corresponds approximately to the height of the flat tube (16). Cooler (12) according to one of the preceding claims, characterized in that at least one flat tube (16) is wave-shaped in a direction perpendicular to the flow direction and perpendicular to the wider side. Cooler (12) according to one of the preceding claims, characterized in that at least one flat tube (16) and/or at least one fluid connection (24) and/or the tank (18) has a stop (54). Cooler (12) according to one of the preceding claims, characterized in that the tank (18) and seal (32) are soldered together. Cooler (12) according to one of the preceding claims, characterized in that the seal (32) is essentially rectangular in a plan view. Radiator (12) according to one of the preceding claims, characterized in that the seal (32) has a substantially uniform thickness. Cooler (12) according to one of the preceding claims, characterized in that the tank (18) has two halves folded parallel to one another and connected by an extension (60). Cooling device (10) with several coolers (12) according to one of the preceding claims, preferably according to one of Claims 5 until 17 , in which the flat tubes (16) are preferably rotated by 180 degrees with respect to adjacent flat tubes (16). Method for producing a cooler (12), in which a flat tube (16) is extruded and punched, a tank (18) is punched from sheet metal and subsequently folded, and the flat tube (16) and tank (18) are soldered together. Procedure according to Claim 19 , characterized in that two fluid connections (24) are also soldered to the tank (18). Procedure according to Claim 20 , characterized in that at least one fluid connection (24) is soldered radially and axially to the tank (18).

Images