U.S. patent application number 11/762626 was filed with the patent office on 2007-12-20 for electric vehicle air cooling system.
Invention is credited to Craig Bliss, Steve Cox, Rui Frias.
Application Number | 20070289561 11/762626 |
Document ID | / |
Family ID | 38626281 |
Filed Date | 2007-12-20 |
United States Patent
Application |
20070289561 |
Kind Code |
A1 |
Cox; Steve ; et al. |
December 20, 2007 |
ELECTRIC VEHICLE AIR COOLING SYSTEM
Abstract
A vehicle that has a propulsion system operable for propelling
the vehicle. The propulsion system includes a heat dissipating
component that generates heat when the propulsion system is
operated. An air cooling system is configured for flowing air
across the heat dissipating component to extract heat therefrom and
has an intake portion that can include a snorkel. The snorkel has
an elongated channel open to the atmosphere at a snorkel intake for
drawing in cooling air and is associated with the heat dissipating
member to deliver cooling air thereto at a location that is
preferably lower than the intake. Also, intake and exhaust plenums
can be provided on upstream and downstream sides of the heat
dissipating components, respectively, to control and direct the
flow of air.
Inventors: |
Cox; Steve; (Tiverton,
RI) ; Bliss; Craig; (Taunton, MA) ; Frias;
Rui; (East Freetown, MA) |
Correspondence
Address: |
WINSTON & STRAWN LLP;PATENT DEPARTMENT
1700 K STREET, N.W.
WASHINGTON
DC
20006
US
|
Family ID: |
38626281 |
Appl. No.: |
11/762626 |
Filed: |
June 13, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60813362 |
Jun 14, 2006 |
|
|
|
Current U.S.
Class: |
123/41.7 |
Current CPC
Class: |
B60Y 2200/12 20130101;
F01P 1/06 20130101; B61C 5/02 20130101; B62K 2204/00 20130101; F01P
5/06 20130101; F01P 1/00 20130101; B60Y 2200/126 20130101; B62K
11/10 20130101; F01P 2050/16 20130101; B60K 1/04 20130101; B60K
2001/005 20130101 |
Class at
Publication: |
123/041.7 |
International
Class: |
F01P 1/02 20060101
F01P001/02 |
Claims
1. A vehicle, comprising: a propulsion system operable for
propelling the vehicle and comprising a heat dissipating component
that generates heat when the propulsion system is operated; an air
cooling system configured for flowing air across the heat
dissipating component to extract heat therefrom, the air cooling
system comprising an intake portion including a snorkel that
includes an elongated snorkel channel open to the atmosphere at a
snorkel intake for drawing in cooling air, the snorkel channel
being associated with the heat dissipating member for delivering
the cooling air thereto at a location lower than the first
location.
2. The vehicle of claim 1, wherein the heat dissipating component
is a vehicle battery.
3. The vehicle of claim 2, wherein the battery comprises a
plurality of batteries, and the cooling system is configured for
flowing the cooling air in parallel across the batteries.
4. The vehicle of claim 3, wherein each battery defines cooling air
passages therethrough for directing the cooling air across the
batteries for extracting heat therefrom, the air passages being
oriented to direct air upwards from a bottom of the batteries,
wherein the snorkel is configured to direct the cooling air to the
bottom of the batteries.
5. The vehicle of claim 1, wherein the air cooling system comprises
an exhaust plenum disposed on a downstream side of the heat
generating component from the snorkel, the plenum being configured
for receiving the cooling air from the heat generating component
and exhausting the cooling air to the atmosphere.
6. The vehicle of claim 5, wherein the plenum defines separate
exhaust channels for air exiting from different locations on the
heat generating component.
7. The vehicle of claim 5, further comprising a vehicle body
comprising a frame portion, wherein the plenum and frame portion
cooperatively define an interior cavity in which the heat
generating component is housed.
8. The vehicle of claim 7, wherein the plenum has sufficient
strength and stiffness to significantly increase the stiffness of
the vehicle body.
9. The vehicle of claim 7, wherein the plenum supports a vehicle
seat for a rider mounted thereon.
10. The vehicle of claim 7, wherein plenum defines separate exhaust
channels for different locations on the heat generating component,
the cooling system comprising an air mover associated with each of
the exhaust channels for moving the cooling air therethrough,
wherein a first of the air movers is disposed longitudinally
forward of the other of the air movers, and one of said locations
on the heat generating component is disposed forward of the air
mover associated therewith.
11. The vehicle of claim 10, wherein the plenum defines a ramp
separating the exhaust channels from each other, with one exhaust
channel extending forward of and above the other at the ramp.
12. The vehicle of claim 11, wherein the exhaust channels are
offset laterally with respect to each other downstream of the
fans.
13. The vehicle of claim 11, wherein the plenum has a forward
portion and a rear portion, the rear portion being vertically
taller than the forward portion and is disposed under a seat area
of the vehicle configured for placement of a seat, wherein the
front portion is sufficiently lower to define a step-through of a
scooter.
14. The vehicle of claim 5, further comprising an intake plenum
connected to direct the cooling air from the snorkel to the heat
dissipating component.
15. The vehicle of claim 1, wherein the snorkel comprises first and
second snorkels, and the intake opening is disposed on an upper
side of a wheel space that is configured for placement of a vehicle
wheel.
16. The vehicle of claim 15, wherein the vehicle wheel is a
steerable front wheel.
17. The vehicle of claim 16, further comprising handle bars in
steering association with the steerable front wheel for steering
the vehicle.
18. A vehicle, comprising: a propulsion system operable for
propelling the vehicle and comprising a heat dissipating component
that generates heat when the propulsion system is operated; an air
cooling system configured for flowing air across the heat
dissipating component to extract heat therefrom, the air cooling
system comprising an exhaust plenum disposed on a downstream side
of the heat dissipating component and to receive the cooling air
from the component and direct the cooling air to the atmosphere,
wherein the plenum defines separate exhaust channels for different
locations on the heat dissipating component; and separate fans
associated with each exhaust channel for moving the cooling air
therethrough.
19. The vehicle of claim 18, wherein the heat generating component
comprises a plurality of batteries, and the plenum defines separate
exhaust channels for different groups of said batteries.
20. The vehicle of claim 18, wherein the cooling system comprises
at least one air mover associated with the plenum for moving the
cooling air through at least one of the exhaust channels.
21. The vehicle of claim 20, wherein the air movers comprise
separate movers associated with each exhaust channel for moving the
cooling air therethrough.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional
application No. 60/813,362, filed on Jun. 14, 2006, the content of
which is hereby incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention relates to an air-cooling system for a
vehicle, and more particularly, to a vehicle with an air-cooling
system configured for flying air across a heat-dissipating
component of a propulsion system.
BACKGROUND OF THE INVENTION
[0003] Vehicles are known to use air cooling or in which a
component of the cooling relies on air flow. In some vehicles, fans
are provided in front or behind a radiator, such as in a liquid
cooled engine. Some electric scooters, for example, have vented
battery compartments, some which have a fan to exhaust the vented
air.
[0004] A vehicle cooling system is needed which can provide
improved air cooling of a heat generating component, such as of a
power source of a vehicle.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a vehicle with an improved
air cooling system. A preferred embodiment of the vehicle includes
a propulsion system that is operable for propelling the vehicle.
The propulsion system has a heat dissipating component that
generates heat when the propulsion system is operated. An air
cooling system of the vehicle is configured for flowing air across
the heat dissipating component to extract heat therefrom. The air
cooling system has an intake portion that includes a snorkel with
an elongated snorkel channel that is open to the atmosphere at a
snorkel intake for drawing in cooling air. The snorkel channel is
associated with the heat dissipating member for delivering the
cooling air thereto at a location that is preferably located lower
than the intake. This arrangement allows the cooling air to be fed
into or near the bottom of the heat generating component, while the
intake is kept high, such as out of road debris that may be kicked
up by a tire, dust, or water.
[0006] The heat dissipating component can be a vehicle battery, and
preferably a plurality of batteries. The cooling system can be
configured for flowing the cooling air in parallel across various
batteries, such as through cooling air passages that are defined
through the batteries to direct the cooling air thereacross. The
snorkel is preferably configured to direct the cooling air to a
bottom side of the batteries or in general to a lower side thereof
in common with the air passages oriented to direct air upwards from
the batteries, although in alternative embodiments, the cooling air
can be directed to a different part of the batteries and made to
flow in a different direction. A plenum is used in the preferred
embodiment, which is disposed downstream of the heat generating
component from the snorkel. The plenum is preferably configured to
receive the cooling air from the heat generating component and for
exhausting the cooling air to the atmosphere. The exhaust plenum
can define separate exhaust channels for air entering from
different locations on the heat generating component, such as from
separate heat generating components, for example, from different
groups of batteries. One or more air movers, such as fans or
blowers, are associated with the plenum for moving the cooling air
through the plenum and the exhaust channels, and preferably
separate air movers are associated with each channel for moving the
cooling air therethrough.
[0007] The preferred plenum is provided as a frame portion of the
vehicle body, and the plenum and another frame portion
cooperatively define an interior cavity in which the heat
generating component is housed. The plenum preferably has
sufficient strength and stiffness to significantly increase the
stiffness of the vehicle body, and preferably sufficient strength
for supporting a vehicle seat on which a rider is to be seated,
such as disclosed in U.S. patent application Ser. No. 10/697,871.
In one embodiment, a plurality of air movers are provided within
the plenum or along another part of the path of the cooling air
through the vehicle body. One of the air movers can be disposed
ahead of the other, and in a scooter, for example, in which a
step-through is to be provided, the various air movers can be
disposed behind the forward most of the heat generating
components.
[0008] The plenum can define a ramp that separates forward and
rear, or upper and lower, exhaust channels from each other, such as
with one exhaust channel extending forward of and above the other
at the location of the ramp. These exhaust channels preferably lead
to the air movers, but can alternatively lead from the air movers.
In other locations, or alternatively, the exhaust channels can be
offset laterally with respect to each other. The preferred plenum
has a rear portion, which can house the air movers, for example,
and a forward portion that is disposed lower than the rear portion,
which allows a step through to be provided above the lower front
portion.
[0009] The snorkel can include first and second snorkels, such as
with the intake openings disposed on an upper side of a wheel space
that is configured for placement of a vehicle wheel, such as a
front wheel. The preferred vehicle has handle bars that are in
steering association with a steerable front wheel for steering the
vehicle. Also, in the preferred embodiment, some or all of the
exhaust cooling-air can be redirected over a heat sink, such as for
a power source controller, to provide increased cooling over the
heat sink.
[0010] Consequently, an improved cooling system is provided, which
is especially useful for cooling batteries that provide motive
energy for an electric-vehicle propulsion-system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side view of a preferred embodiment of a scooter
constructed according to the present invention;
[0012] FIG. 2 is a perspective view of a scooter frame, shown
semi-transparently to show the components housed internally within
the frame;
[0013] FIG. 3 is a cut-away side view of the frame;
[0014] FIG. 4 is a top view of the plenum thereof; and
[0015] FIG. 5 is a perspective view of an intake plate with snorkel
connectors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to FIG. 1, a preferred embodiment of a vehicle
constructed according to the invention is a scooter 100, which
includes a frame 10 on which a plurality of components are mounted.
These components include fairings 102, that cover the structural
components of the underlying frame 10. Seat 104 is mounted on the
frame 10, and is preferably directly mounted to and supported by an
upper portion of the frame, which in this embodiment is preferably
an exhaust plenum 44. A swing-arm 106 is pivotably connected to the
frame 10, and shocks between the swing-arm 106 and frame 10 are
absorbed by shock absorber/spring 108. A propulsion system is
provided that includes a motor or an engine, and the preferred
embodiment includes a motor 110, which can be housed in the
swing-arm 106 or elsewhere on the vehicle. The propulsion system
also includes batteries 20, which are housed within a closed
interior cavity of the frame, which cavity is preferably defined
cooperatively between upper and lower frame portions. The upper
portion of the frame 10, which in the preferred embodiment is
plenum 44, can be removed from the lower frame portion to open the
interior space and provide access to the batteries, such as for
removing the batteries therefrom.
[0017] At a front end of the frame, a steering tube 110 is
preferably received within a head tube 14 for rotation to steer
front wheel 112. In alternative embodiments, other steering
arrangements can be employed. The preferred embodiment is a land or
road vehicle, having two wheels, three wheels, or more. In one
embodiment, the vehicle is driven by a component other than
wheels.
[0018] Referring to FIGS. 1-4, vehicle frame 10 includes a
framework of welded elongated struts 12, and is preferably
constructed as disclosed in U.S. patent application Ser. No.
10/697,871. The struts are preferably configured to provide a lower
frame portion. The lower frame portion preferably includes the head
tube 14, configured for rotatably receiving steering tube 110,
which preferably has a wheel fork 112, and which is steered by
handle bars 114, on which a twist throttle 116 can be mounted. The
openings on the outside of the lower frame portion are sealed by
skins 16, preferably structural skins that are welded or bolted to
the struts 12. The lower frame portion defines a lower side of an
interior cavity 18 within the framework that is configured to house
a portion of a propulsion system, which preferably includes
batteries 20, or another energy storage component, such as
capacitors. Footrest supports 22 are welded, or otherwise mounted
or fixed to the lower frame portion, preferably to the struts 12.
While the skins 16 are preferably secured to the struts 12 to
stiffen the lower frame portion, particularly in longitudinal
torsion about a longitudinal axis extending from front to back of
the vehicle, alternative embodiments can have other skins that
close, and preferably seal, the sides of the interior cavity 18,
but which can be non-structural.
[0019] A bottom tray portion 24 closes off a bottom side of the
bottom frame portion, and is configured for supporting the
batteries 20. An internal battery tray 26 is spaced from the
external tray 24 to provide an intake air plenum 28 therebetween to
allow air to flow underneath the batteries 20.
[0020] At the front of the lower frame portion, frame skin 16
preferably closes off an upper portion of the front side of the
interior cavity 18. On a bottom portion of the front side is
preferably a front plate 30, shown in detail in FIG. 5, which
includes one or more intake conduits connectors 32. Connectors 32
define an open channel 34 therein, which is connected to the intake
air plenum 28 to feed cooling air thereto. In the preferred
embodiment, two intake connectors 32 are provided, which are placed
on lateral left and right sides of the front plate 30. FIG. 3 shows
an example of an alternate position for the intake connectors 39,
which are shown in phantom lines, and are placed on the lateral
sidewalls of the exterior battery tray 24.
[0021] Snorkels 36 are connected to the connectors 32, and define
an elongated, interior snorkel-channel that is open to the
atmosphere at snorkel intakes 38. The intakes 38 are preferably
oriented in alignment with the local airflow to take advantage of
ram air pressure when the vehicle is moving in a forward direction,
although other orientations can be used. As shown in FIG. 1, the
intakes 38 can be disposed in the wheel space 118 for the front,
steerable wheel 112, preferably above mud guard 120 to receive
clean air, with the mud guard deflecting any road debris or dust.
The intakes 38 are also preferably concealed from view by a head
faring 122, being disposed therebeneath The snorkels 36 draw in
cooling air 78 from the atmosphere and direct the air 78 into the
intake plenum 28. The snorkels 36 can be made of a rigid material,
and in the embodiment shown are made of flexible tubing which is
attached to the connectors 32 and to the lower frame portion, such
as by clamps or wraps 40. The snorkels 36 preferably extend
adjacent the front tire of the vehicle, and are preferably disposed
to permit the front tire to rotate left and right without
interfering with the snorkels. Similarly, the connectors 32 have
angled surfaces 42 to enable the tire to be turned without bumping
up against the connectors 32. In alternative embodiments, the
connectors have other shapes, but are disposed far enough back,
vertically, and/or to the lateral sides to avoid interference with
the tire in any steering position.
[0022] The batteries 20 are arranged with cooling channels 42 that
are open to the intake plenum 28. The cooling channels 42
preferably extend in a generally vertical direction and are open
and top and bottom ends of the batteries 20. In one embodiment, the
batteries themselves are configured with channels 42, and in
another embodiment the batteries 20 include a plurality of
batteries, preferably arranged in groups such as stacks and
arranged with respect to each other such that air passages 42
extend therebetween or therethrough.
[0023] The plenum 44 is preferably made of a material and a
configuration selected to provide sufficient strength and rigidity
to substantially increase the stiffness of the lower frame portion,
especially the torsional stiffness thereof, and to prevent the
horizontally extending struts 12 at the top of the lower frame
portion from buckling, since these upper horizontal struts 12 are
in compression when the vehicle is supported on front and rear
wheels.
[0024] The preferred plenum is bolted with bolts 46 or other
fasteners to couple the plenum with the lower frame portion. A
forward portion 48 of the plenum is disposed at a lower height that
a rear portion 50 of the plenum to provide a step-through, such as
in the case that the vehicle is a scooter. In a motorcycle or other
vehicle embodiment, the forward portion of the plenum can be as
high or higher than the rear portion 50.
[0025] Referring to FIGS. 2-4, preferably in the rear portion 50,
one or more blowers, fans 52,54, or other device to move the
cooling air through the plenum are housed. Baffling 56 is
preferably provided to capture the air 78 separately from forward
and rear batteries 20 to direct the air from the forward batteries
to the forward fan 52 and the air 78 from the rear batteries to the
rear fan 54. Exit baffling 58 can also be provided to maintain
separate the air flowing from each fan 52,54 and to direct the air
towards an exit 60, which is preferably open to the atmosphere. The
preferred fans are centrifugal fans that have an intake 62 on a
bottom side thereof, and a tangential exit 64, which is aligned
with the baffling. As shown in FIG. 1, the forward batteries are
preferably disposed partially or entirely forward of the forward
fan 52.
[0026] As seen in FIG. 3, the upstream side of the plenum baffling
includes a substantially vertical wall 66, which leads to an
inclined wall, for example forming a ramp 68, to define a first
plenum portion 70. The first plenum portion leads the cooling air
from the forward batteries 20 to the forward fan 52. This baffling
portion separates the forward plenum portion 70 from the rear
plenum portion 72, which thus preferably operates as a separate
plenum. In an alternative embodiment, a common plenum can be
employed for additional portions of the batteries or all of the
batteries. On the exit side of the plenum, downstream from the fans
52,54, plenum channels are defined by additional baffling 72, which
is configured to provide separate exit channels for air 78 coming
from the forward fan 52 and the rear fan 54. In the preferred
embodiment, the baffling 72 in the plenum 44 is integrally and
unitarily formed with the rest of the plenum, but alternative forms
of baffling can be used, and the channels, both upstream and
downstream of the fans 52,54 are separated only by the baffles,
which form walls between the adjacent channels.
[0027] Seals 74 are preferably used to seal the exit area of the
plenum from the intake area of the plenum 44. The fans 52,54 and
the exhaust channels downstream from the fans 52,54, preferably
direct the cooling air generally horizontally or substantially
parallel to the seat 104. The exit area of the plenum is configured
to provide the two exit channels laterally displaced with respect
to each other, i.e., one to the left and one to the right, and the
exit channel from the fan 52 is configured to extend laterally
and/or vertically around the side of the space occupied by fan 54.
As seen in FIG. 3, the plenum exit opening 60 is preferably angled
downwards, although other orientations can be used. In the
preferred embodiment the exit air is aimed and blown over heat
sinks 76 of another heat generating component, such as a controller
that controls the power to the motor 110.
[0028] With reference to FIG. 3, cooling air 78 is drawn into
snorkels 36 and is directed to the intake plenum 28. From here, the
cooling air 78 is drawn in parallel upwards across the batteries,
preferably by passing through cooling channels 42, into the intake
portions 70 and 72 of the plenum 44, Fans 52,54, which are drawing
the air through the intake side of the system, then blow the air
through the exit portion of the plenum and out the exit 60, at
which point the cooling air can further be used to increase the air
flow and increase cooling over heat sink 76, which can comprise a
plurality of cooling fins and is preferably located at a back wall
of the frame. To assist the proper pathway that the cooling air 78
follows in the intake plenum, a seal 80, shown in dashed lines in
FIG. 2, can be used to seal the intake plenum to the batteries.
Additionally, or alternatively, an exhaust plenum seal can be
provided to seal the upper plenum to the batteries, such as at
dashed line 82, to prevent or reduce cooling air spillage around
the batteries or around another area that is desired to be cooled.
The cooling air preferably flows along two parallel paths from
where it comes into contact with the batteries 20 until it reaches
the fans 52,54, and also preferably downstream of the fans
52,54.
[0029] Suitable propulsion systems for electric and hybrid
embodiments of the inventive vehicle are disclosed in the copending
application filed on Jun. 14, 2006, entitled, "Vehicle With
Contactless Throttle Control". The entire contents of said
copending application and of U.S. patent application Ser. No.
10/697,871 are hereby incorporated herein by reference thereto.
[0030] While illustrative embodiments of the invention are
disclosed herein, it will be appreciated that numerous
modifications and other embodiments can be devised by those skilled
in the art. Features of the embodiments described herein, can be
combined, separated, interchanged, and/or rearranged to generate
other embodiments. Therefore, it will be understood that the
appended claims are intended to cover all such modifications and
embodiments that come within the spirit and scope of the present
invention.
* * * * *