Cooling of heat-generating components in electric vehicles

Abstract

The electric vehicle (EV) includes a frame extending rearward from a front portion of the EV toward a rear portion of the EV. A floor structure is disposed below the frame and supported by the frame. A battery is disposed in a cavity defined between the floor structure and the frame. A first heat-generating component is disposed within the rear portion of the EV. The EV further includes a duct extending from the front portion to the first heat-generating component to guide air from the front portion to the first heat-generating component.

Description

[Technical field]

[0001] The present invention relates to cooling heat generating components in vehicles, such as electric vehicles (EVs). [Background technology]

[0002] Vehicles, such as electric vehicles (EVs), include heat-generating components such as electric motors, controllers, etc. The heat-generating components generate heat during operation of the EV. Summary of the Invention [Problem to be solved by the invention]

[0003] Heat-generating components, such as electric motors, controllers, etc., generate heat during operation of an EV. Cooling the heat-generating components to prevent overheating of the heat-generating components may require transporting the generated heat away from the components. However, removing heat from such heat-generating components may be an energy-consuming process and may affect the performance of the EV. For example, cooling components, such as cooling fans, may be implemented within the EV to remove the heat. The cooling components may increase the electrical load on the EV's electric motor, thereby increasing the power consumption of the EV. As a result, the efficiency of the EV may decrease. Furthermore, noise generated by the cooling fans may reduce the driving experience of a user of the EV. [Means for solving the problem]

[0004] The present invention relates to cooling heat generating components in electric vehicles (EVs). Effect of the Invention

[0005] Through embodiments of the present invention, heat-generating components within an EV can be easily and efficiently cooled. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a right side view of an electric vehicle (EV) according to an embodiment of the present invention. [Diagram 2] FIG. 1 is a front view of an EV according to an embodiment of the present invention. [Figure 3a] FIG. 2 is a top view of an EV according to an embodiment of the present invention. [Figure 3b] FIG. 2 is a right side view of an EV according to an embodiment of the present invention. [Figure 3c] FIG. 1 is a front view of an EV according to an embodiment of the present invention. [Figure 4a] FIG. 2 is a right side view of an EV according to an embodiment of the present invention. [Figure 4b] FIG. 4b is an enlarged view of a portion shown in FIG. 4a according to an embodiment of the present invention. [Figure 5a] FIG. 2 is a left side view of an EV according to an embodiment of the present invention. [Figure 5b] FIG. 5b is an enlarged view of a portion shown in FIG. 5a according to an embodiment of the present invention. [Figure 6a] FIG. 2 is a perspective view of a duct facing an electric motor according to an embodiment of the present invention. [Figure 6b] FIG. 6b is a top view of the duct shown in FIG. 6a according to an embodiment of the present invention. [Figure 7a] FIG. 2 is a perspective view of a duct according to an embodiment of the present invention. [Figure 7b] FIG. 2 is a perspective view of a duct according to an embodiment of the present invention. [Figure 7c] FIG. 2 is a top view of a duct according to an embodiment of the present invention. [Figure 7d] FIG. 2 is a left side view of a duct according to an embodiment of the present invention. [Figure 7e] FIG. 2 is a front view of a duct according to an embodiment of the present invention. [Figure 7f] FIG. 2 is a right side view of a duct according to an embodiment of the present invention. [Figure 8] 1 is a perspective view of a combination of a duct, a floor plate attachment, and a floor plate structure according to an embodiment of the present invention. [Figure 9] FIG. 2 is an exploded view of a combination of a floor plate mounting, a duct, and a floor plate structure according to an embodiment of the present invention. [Figure 10]FIG. 2 is an exploded view of a floor panel attachment, floor panel structure, and ducting from an EV according to an embodiment of the present invention. [Figure 11a] FIG. 1 is a perspective view of an EV according to an embodiment of the present invention. [Figure 11b] FIG. 1 is a front view of an EV according to an embodiment of the present invention. [Figure 12a] FIG. 2 is a right side view of an EV according to an embodiment of the present invention. [Figure 12b] FIG. 2 is a perspective view of a duct and cowl combination of an EV according to an embodiment of the present invention. [Figure 12c] FIG. 2 is a top view of a duct and cowl combination of an EV according to an embodiment of the present invention. [Figure 13a] FIG. 2 is a top view of an EV according to an embodiment of the present invention. [Figure 13b] FIG. 2 is a right side view of an EV according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] The present invention will now be described in detail with reference to the accompanying drawings, in which the left-most digit of a reference number identifies the figure in which the reference number first appears, and the same numbers are used throughout the figures to reference like features and components.

[0008] According to an exemplary embodiment of the present invention, an electric vehicle (EV) may include a frame and a floorboard structure. The frame may extend rearwardly from a front portion of the EV toward a rear portion of the EV. The floorboard structure may be disposed below the frame and may be supported by the frame. In one example, the floorboard structure may be coupled to the frame through floorboard attachments. Further, a cavity may be defined between the floorboard structure and the frame. A battery of the EV may be disposed within the cavity.

[0009] The EV may include a first heat-generating component disposed within a rear portion of the EV. The first heat-generating component may be, for example, an electric motor. To cool the first heat-generating component, the EV may include a duct extending rearward from the front portion toward the first heat-generating component.

[0010] When the duct extends rearward, a portion of the duct can be disposed above the battery. Air flowing within a front portion of the EV can enter the duct, and the duct can direct the air to the first heat-generating component. The air directed by the duct can flow over the first heat-generating component to facilitate cooling of the first heat-generating component.

[0011] The present invention allows for easy and efficient cooling of heat-generating components such as electric motors, controllers, etc. in an EV. Furthermore, since the present invention utilizes the air flowing in the front portion of the EV to cool the heat-generating components, the present invention can prevent the utilization of additional cooling components such as cooling fans. Thus, the present invention reduces energy, which in turn results in increased performance of the EV. By preventing the utilization of cooling components, the present invention also prevents noise generated by the cooling components.

[0012] The present invention is further described with reference to Figures 1-15. It should be noted that the description and figures merely illustrate the principles of the present invention. Although not explicitly described or shown herein, various arrangements embodying the principles of the present invention may be contemplated. Moreover, all statements herein reciting the principles, aspects, and examples of the present invention, as well as specific examples thereof, are intended to encompass their equivalents.

[0013] Some of the terms used in the following description and their meanings are explained below.

[0014] The forward direction refers to the direction from the rear wheels to the front wheels of the EV. The rear direction refers to the direction from the front wheels to the rear wheels of the EV. The forward and rear directions may be referred to as length directions when the EV extends forward and rearward in length. The midpoint (M) of the EV refers to the midpoint along the length, span and width of the EV. The forward portion refers to the front half of the vehicle along the length. The rear portion refers to the rear half of the vehicle along the length of the EV. The left hand side refers to the left hand side of the EV when looking at the EV from the front of the EV. The right hand side refers to the right hand side of the EV when looking at the EV from the front of the EV.

[0015] 1 illustrates a right side view of an electric vehicle (EV) 100, according to an embodiment of the present invention. The EV 100 may include a frame 101 for facilitating coupling of and supporting the components of the EV 100. For example, the frame 101 may provide structural support to the components of the EV 100 to withstand loads acting on the EV 100, such as the weight of a driver (not shown in FIG. 1), forces due to cross winds, etc. In one example, the frame 101 may extend from a front portion 102 of the EV 100 toward a rear portion 103 of the EV 100.

[0016] The EV 100 may include a battery 104 for powering the EV 100. Additionally, the EV 100 may include a heat-generating component, such as a first heat-generating component. The first heat-generating component may be, for example, an electric motor (not shown in FIG. 1 ) that may receive power from the battery 104 of the EV 100 to propel the EV 100. Hereinafter, the first heat-generating component may be described with reference to the electric motor. During operation, the electric motor may generate heat. For example, the electric motor may generate heat when it operates to propel the EV 100.

[0017] The EV 100 may include a front panel 105, front wheels 106, a front wheel suspension assembly 107, and side panels 108 in a front portion 102. The EV 100 may include rear wheels 110 and a transmission system 112 in a rear portion 103.

[0018] In one example, the side panels 108 may serve the purpose of protecting the heat-generating components from structural damage caused to the heat-generating components and may improve the aesthetics of the EV 100. Additionally, the side panels 108 may prevent direct exposure of the heat-generating components to air, which may cause the heat-generating components to overheat.

[0019] To prevent overheating of the heat-generating components, the EV 100 may include a duct 114. The duct 114 may direct air to the heat-generating components to prevent overheating of the heat-generating components. In one example, the duct 114 may direct air from a front portion 102 of the EV 100 to the heat-generating components. In one example, the duct 114 may be a load-bearing member. For example, the duct 114 may be part of the frame 101, and a portion of the load acting on the frame 101 may act on the duct 114.

[0020] FIG. 2 shows a front view of an EV 100 according to an embodiment of the present invention. The EV 100 may include a front wheel fender 204 that may be disposed above the front wheel 106 at a front portion 102 of the EV 100. The front wheel fender 204 may be curved or flat, for example. Furthermore, the front wheel suspension assembly 107 may include a first fork 208 and a second fork 210. The first fork 208 may be on a left hand side 212 and the second fork 210 may be on a right hand side 214. The front wheel suspension assembly 107 may further include a suspension bracket 216 (referred to as a "lower suspension bracket") to which the first fork 208 and the second fork 210 may be coupled. The lower suspension bracket 216 may be disposed above the front wheel fender 204 such that a gap 220 is defined between the lower suspension bracket 216 and the front wheel fender 204. The lower suspension bracket 216 may be flat or curved, for example, relative to the gap 220 .

[0021] The inlet 222 of the duct 114 may face the front portion 102 of the EV 100 to direct air from the front portion 102 of the EV 100 to the electric motor (not shown in FIG. 2 ). In one example, the inlet 222 may face the gap 220 and receive air from above the front wheel fender 204.

[0022] 3a shows a top view of an EV 100, according to an embodiment of the present invention. Depicted therein is a frame 101, which can extend rearwardly from a front portion 102 of the EV 100 towards a rear portion 103 of the EV 100.

[0023] In one example, the frame 101 may be coupled to a head pipe 302. The head pipe 302 may be disposed, for example, in the front portion 102 to facilitate steering of the EV 100. The frame 101 may extend rearward from the head pipe 302 toward a rear portion 103 of the EV 100.

[0024] In one example, the frame 101 may include a first frame member 304 and a second frame member 306. The first frame member 304 may extend from the head pipe 302 along the right hand side 214 towards the rear portion 103. The second frame member 306 may extend from the head pipe 302 along the left hand side 212 towards the rear portion 103. The frame 101 may include a third frame member 308 coupled to the first frame member 304 and the second frame member 306 and extending rearwardly therefrom. The third frame member 308 may have a substantially U-shaped structure and may be coupled to a seat (not shown in FIG. 3a) for supporting the seat. The frame 101 may be, for example, a perimeter frame, a monocoque frame, a trellis frame or a cradle frame. In one example, the first frame member 304, the second frame member 306 and the third frame member 308 may be hollow or solid rods.

[0025] FIG. 3b shows a right side view of EV 100, according to an embodiment of the present invention.

[0026] The EV 100 may include a floorboard structure 310 disposed below and supported by the frame 101. The floorboard structure 310 may be disposed rearward of the front wheels 106. Furthermore, the floorboard structure 310 may be substantially horizontal in shape and may be supported by the frame 101. For support, the floorboard structure 310 may be coupled to the frame 101 through a floorboard attachment 312, which may be substantially vertical. In one example, the floorboard attachment 312 may be coupled to the floorboard structure 310 at a front end 314 of the floorboard structure 310.

[0027] Additionally, the floorboard structure 310 can act as a floor upon which components of the EV 100, such as the battery 104, can be mounted. In one example, the battery 104 can be disposed within a cavity 316 defined between the floorboard structure 310 and the frame 101.

[0028] The electric motor 318 may be disposed rearward of the floorboard structure 310 and may receive power from the battery 104 to propel the EV 100. In one example, the electric motor 318 may be located entirely within the rear portion 103 and may be coupled to the frame 101 at the rear portion 103. In another example, a portion of the electric motor 318 may be disposed within the front portion 102 and a remaining portion of the electric motor 318 may be disposed within the rear portion 103. In a further example, the electric motor 318 may be located entirely within the front portion 102.

[0029] The duct 114 may extend from the front portion 102 toward the electric motor 318 to guide air from the front portion 102 to the electric motor 318. As a result, air from the front portion 102 may be supplied to the electric motor 318, which may cool the electric motor 318. In one example, the inlet 222 of the duct 114 may be disposed above the front wheel fender 204 (not shown in FIG. 3b) to receive air from the front portion 102. Furthermore, when the duct 114 may extend from the front portion 102 toward the electric motor 318, a portion of the duct 114 may be disposed above the battery 104 to avoid obstruction to the battery 104.

[0030] The EV 100 may include a second heat generating component disposed within the cavity 316. The second heat generating component may be, for example, a controller 322 that may control the operation of the electric motor 318. Hereinafter, the second heat generating component may be described with reference to the controller 322. The controller 322 may be disposed within the cavity 316 adjacent to the battery 104.

[0031] FIG. 3c shows a front view of EV 100 according to an embodiment of the present invention.

[0032] The first fork 208 can be coupled to the head pipe 302 and can extend downwardly on a left hand side 212 toward the front wheel 106. The second fork 210 can be coupled to the head pipe 302 and can extend downwardly on a right hand side 214 toward the front wheel 106.

[0033] The front wheel 106 may be disposed below the head pipe 302 and may be coupled to the first fork 208 and the second fork 210. For example, each of the first fork 208, the second fork 210 may have a top end (not shown in FIG. 3c) and a bottom end (not shown in FIG. 3c). The top ends of the first fork 208 and the second fork 210 may be coupled to the head pipe 302, and the bottom ends of the first fork 208 and the second fork 210 may be coupled to the front wheel 106.

[0034] In one example, the front wheel fender 204 may be disposed above the front wheel 106 and below the suspension bracket 216. Additionally, the front wheel fender 204 may extend above the front wheel 106 along a portion of the front wheel 106 and between the first fork 208 and the second fork 210.

[0035] As mentioned above, the inlet 222 of the duct 114 can face the gap 220 and receive air from the front portion 102. In one example, the inlet 222 can have a width and height large enough to ensure that a large amount of air enters the duct 114 and is supplied to the heat-generating components for cooling. Thus, the height and width of the inlet 222 can be selected based on the size of the heat-generating components and the amount of heat they generate. Also, the dimensions of the inlet 222 of the duct 114, such as the width and height, can be determined by the distance between the first fork 208 and the second fork 210 and the distance between the lower suspension bracket 216 and the front wheel fender 204. For example, the width of the inlet 222 can be determined by the distance between the first fork 208 and the second fork 210, and the height of the inlet 222 can be determined by the distance between the lower suspension bracket 216 and the front wheel fender 204.

[0036] 4a shows a right side view of the EV 100, in accordance with an embodiment of the present invention, where some of the components, such as the side panel 108, the battery 104, etc., are not shown in order to clearly illustrate the duct 114.

[0037] In one example, the inlet 222 may be located a distance away from the gap 220 along the length. In some examples, the inlet 222 of the duct 114 may be located in the gap 220. Further, air flowing within the front section 102 may enter the inlet 222 through the gap 220 and be supplied to the electric motor 318 through an outlet 402 (hereinafter referred to as a "first outlet") facing the electric motor 318. In some examples, depending on the design of the EV 100 and the heat generated by the electric motor 318, the duct 114 may include multiple outlets facing the electric motor 318, each outlet for supplying air to the electric motor 318.

[0038] Figure 4b shows an enlarged view of the portion shown in Figure 4a, according to an embodiment of the present invention, depicting air entering the front section 102 through gap 220 into inlet 222. In the front section 102, duct 114 may be rigidly coupled to frame 101 through floor plate attachment 312.

[0039] 5a shows a left side view of the EV 100, in accordance with an embodiment of the present invention, where some of the components, such as the side panel 108, the battery 104, etc., are not shown in order to clearly illustrate the duct 114.

[0040] In one example, in addition to supplying air to the electric motor 318, the duct 114 can supply air to the controller 322 through an outlet 502 (hereafter referred to as the “second outlet”) facing the controller 322. For example, a portion of the air entering the inlet 222 through the gap 220 can be supplied to the electric motor 318, and the remaining portion of the air entering the inlet 222 of the duct 114 can be supplied to the controller 322. In some examples, depending on the design of the EV 100 and the heat generated by the controller 322, the duct 114 can include multiple outlets facing the controller 322, each outlet for supplying air to the controller 322.

[0041] In some examples, the duct 114 can supply air to the battery 104 (not shown in FIG. 5a). The duct 114 can thus be provided with one or more outlets facing the battery 104 to supply air to the battery 104 and prevent the battery 104 from overheating.

[0042] FIG. 5b shows an enlarged view of the portion shown in FIG. 5a according to an embodiment of the present invention, where the supply of air entering the electric motor 318 and the controller 322 is depicted. A portion of the duct 114 can extend rearward toward the electric motor 318 and can supply air to the electric motor 318 through the first outlet 402. As can be appreciated, in the illustrated view, that portion of the duct 114 can be disposed rearward of the controller 322. Additionally, another portion of the duct 114 can extend toward the controller 322 and can supply air to the controller 322 through the second outlet 502.

[0043] FIG. 6a shows a perspective view of the duct 114 facing the electric motor 318, according to an embodiment of the present invention.

[0044] The shape of the duct 114 may be designed while considering the dimensions of the components mounted on the floor plate structure 310 (not shown in FIG. 6a) and the arrangement of the components within the floor plate structure 310. For example, the battery 104 may be placed within the floor plate structure 310 and may occupy most of the cavity 316 (not shown in FIG. 6a). Thus, the duct 114 may be designed in such a way that it passes through the remaining portion of the cavity 316 that is not occupied by the battery 104. For example, the portion of the duct 114 that extends through the cavity 316 may be located above all of the components, such as the battery 104, the interface box, etc., that are mounted on the floor plate structure 310 and occupy within the cavity 316. Thus, there is no need to redesign such components, i.e., such components may be utilized without any change in dimensions. Also, such components may not have to be arranged differently to accommodate the duct 114 within the cavity 316. Furthermore, as the duct 114 traverses the components disposed within the cavity 316, the duct 114 may move downward to face the electric motor 318. For example, as the duct 114 travels to extend rearward, after passing the edge of the battery 104, the duct 114 may move downward to face the electric motor 318.

[0045] The duct 114 may include a number of front mounting supports 604 on an upper surface 606 of the duct 114. The upper surface 606 may be, for example, a surface of the duct 114 near the frame 101 (not shown in FIG. 6a). The front mounting supports 604 may facilitate mounting the duct 114 to the frame 101 at the front portion 102 (not shown in FIG. 6a) by utilizing fasteners 607, such as bolts. Additionally, at the rear portion 103 (not shown in FIG. 6a), the duct 114 may be mounted to the frame 101 through a number of rear mounting supports 608, which may be provided on the upper surface of the duct 114.

[0046] In one example, the electric motor 318 can include a number of fins 610. The presence of the fins 610 increases the surface area of ​​the electric motor 318. As a result, a greater amount of heat can be dissipated from the electric motor 318 in a shorter period of time.

[0047] FIG. 6b shows a top view of the duct 114 shown in FIG. 6a, according to an embodiment of the present invention.

[0048] In one example, the duct 114 may branch into two, such as a first branch 614 and a second branch 616, as it approaches the rearward direction. For example, a portion of the duct 114 that may extend toward the electric motor 318 may be referred to as the first branch 614. The first branch 614 may have a first outlet 402 (not shown in FIG. 6b) that faces the electric motor 318. A portion of the duct 114 that extends toward the controller 322 may be referred to as the second branch 616. The second branch 616 may have a second outlet 502 (not shown in FIG. 6b) that may face the controller 322. In one example, the length of the second branch 616 may be shorter than the first branch 614 because the controller 322 is located closer to the inlet 222 (not shown in FIG. 6b) than the electric motor 318.

[0049] The air entering the inlet 222 may be split, and a portion of the air may enter the first branch 614 and be provided to the electric motor 318 through the first outlet 402. The remaining portion of the air may enter the second branch 616 and be provided to the electric motor 318 through the second outlet 502. The relative sizes of the first outlet 402 and the second outlet 502 may be determined based on the amount of heat generated by the electric motor 318 and the controller 322. Because the amount of heat generated by the electric motor 318 is greater than the amount of heat generated by the controller 322, a greater amount of air may be provided to the electric motor 318 compared to the controller 322. Thus, in one example, the size of the first outlet 402 may be greater than the second outlet 502.

[0050] In one example, the duct 114 can include multiple branches, each of which can have an outlet, with each outlet facing a respective one of the multiple heat-generating components of the EV 100. Thus, air from the front portion 102 (not shown in FIG. 6b) of the EV 100 can be supplied to the heat-generating components through the outlet of the branch facing the corresponding heat-generating component. In some examples, each branch of the multiple branches of the duct 114 can include multiple outlets, with each outlet facing the heat-generating component to supply air to the corresponding heat-generating component. Further, in some examples, some or all of the outlets of each of the multiple branches of the duct 114 can face the heat-generating component to supply air to the corresponding heat-generating component.

[0051] 7a shows a perspective view of the duct 114 according to an embodiment of the present invention. In one example, the duct 114 may be of rectangular cross-section. The height and width of the inlet 222 may be selected based on the size of the heat generating component and the amount of heat it generates.

[0052] Figure 7b shows a perspective view of the duct 114 according to an embodiment of the present invention. As mentioned above, the duct 114 has a first outlet 402 for supplying air to the electric motor 318 (not shown in Figure 7b) and a second outlet 502 for supplying air to the controller 322 (not shown in Figure 7b).

[0053] The duct 114 has a front mounting support 604 for connecting the duct 114 to the frame 101 at the front portion 102 (not shown in FIG. 7b) and a rear mounting support 608 for connecting the duct 114 to the frame (101) (not shown in FIG. 7b) at the rear portion 103 (not shown in FIG. 7b).

[0054] 7c shows a top view of duct 114 according to an embodiment of the invention. Duct 114 may include a first branch 614 and a second branch 616. First branch 614 may extend towards electric motor 318 to supply air to electric motor 318 (not shown in FIG. 7c), and second branch 616 may extend towards controller 322 to supply air to controller 322 (not shown in FIG. 7c).

[0055] Figure 7d shows a left side view of the duct 114 according to an embodiment of the invention. The height and width of the inlet 222 of the duct 114 may be determined by the distance between the first fork 208 (not shown in Figure 7d) and the second fork 210 (not shown in Figure 7d) and the distance between the lower suspension bracket 216 (not shown in Figure 7d) and the front wheel fender 204 (not shown in Figure 7d) to maximize the amount of airflow entering the inlet 222 from the front portion 102 (not shown in Figure 7d).

[0056] FIG. 7e illustrates a front view of the duct 114 according to an embodiment of the present invention. The duct 114 is designed and positioned in such a manner that it may avoid interference with components disposed within the cavity 316 (not shown in FIG. 7e). Thus, a portion of the duct 114 passing through the cavity 316 may be disposed above components occupying the cavity 316, such as the battery 104 (not shown in FIG. 7e), an interface box, etc. Furthermore, upon crossing the components disposed within the cavity 316, the first branch 614 of the duct 114 may move downward to face the electric motor 318 (not shown in FIG. 7e), and the second branch 616 (not shown in FIG. 7e) may move downward to face the controller 322. In this regard, the components disposed within the cavity 316 may not have to be redesigned or positioned differently to accommodate the duct 114 within the cavity 316.

[0057] 7f illustrates a left side view of the duct 114, according to an embodiment of the present invention. The first outlet 402 may face the electric motor 318 (not shown in FIG. 7f) to supply air to the electric motor 318. Because the electric motor 318 may generate a greater amount of heat than the controller 322 (not shown in FIG. 7f), the amount of air supplied to the electric motor 318 may be greater. Thus, to facilitate supplying a greater amount of air to the electric motor 318, the dimensions of the first outlet 402 may be greater than the dimensions of the second outlet 502 (not shown in FIG. 7f).

[0058] FIG. 8 illustrates a perspective view of the combination of a duct 114, a floor plate attachment 312 and a floor plate structure 310, in accordance with an embodiment of the present invention.

[0059] In one example, the floorboard structure 310 can be attached to the frame 101 (not shown in FIG. 8) via the floorboard attachment 312. That is, the floorboard structure 310 can be coupled to the floorboard attachment 312, and the floorboard attachment 312 can be coupled to the frame 101 (not shown in FIG. 8). For example, the bottom end 801 of the floorboard attachment 312 can be coupled to the top end 802 of the floorboard structure 310, and the top end 804 of the floorboard attachment 312 can be coupled to the frame 101. The floorboard attachment 312 can be, for example, an inverted U-shaped structure. Furthermore, the floorboard structure 310 can be coupled to the floorboard attachment 312, for example, through a first bracket 806 and a second bracket 808.

[0060] To facilitate mounting the duct 114 to the frame 101 at the front portion 102 (not shown in FIG. 8 ), a floor plate attachment 312 may be utilized. For example, the duct 114 may be coupled to the floor plate attachment 312. However, in some instances, the duct 114 may be coupled directly to the frame 101.

[0061] The duct 114 can be coupled to the floor plate mounting body 312 by fastening the front mounting support 604 to the upper end 804 of the floor plate mounting body 312, so that the inlet 222 can be disposed below the upper end 804 of the floor plate mounting body 312 and attached to the inverted U-shaped structure, and the inlet 222 can face the front portion 102. Therefore, the inlet 222 of the duct 114 can be said to be coupled to the upper end 804 of the floor plate mounting body 312. Furthermore, the fastening of the front mounting support 604 to the floor plate mounting body 312 can be by fasteners 607 such as bolts. The inner width of the floor plate mounting body 312 can be larger than the width of the duct 114 to accommodate the duct 114 within the floor plate mounting body 312.

[0062] In one example, the duct 114 may be coupled to the frame 101 at the rear portion 103 by utilizing rear mounting supports 608. For example, the rear mounting supports 608 may be coupled to brackets 811 (hereinafter referred to as “frame brackets”) to attach the duct 114 to the frame 101.

[0063] Furthermore, as mentioned above, the duct 114 is designed in such a manner that it can avoid interference with components disposed within the cavity 316 (not shown in FIG. 8 ), such as the battery 104 (not shown in FIG. 8 ), the contactor 812, and the interface box 814 disposed within the cavity 316.

[0064] FIG. 9 illustrates an exploded view of the combination of floor plate attachment 312, duct 114, and floor plate structure 310, according to an embodiment of the present invention.

[0065] To facilitate fastening the duct 114 to the floor plate mount 312, in one example, the floor plate mount 312 can include a third bracket 902 and a fourth bracket 904 at the upper end 804. The front mounting support 604 can be coupled to the third bracket 902 and the fourth bracket 904. Additionally, the rear mounting support 608 of the duct 114 can be coupled to a frame bracket 811 to mount the duct 114 to the frame 101 (not shown in FIG. 9 ). The coupling between the rear mounting support 608 and the frame bracket 811 can be by fasteners 905, such as bolts.

[0066] Additionally, as mentioned above, the fins 610 of the electric motor 318 can facilitate faster heat dissipation from the electric motor 318. In one example, the fins 610 of the electric motor 318 can be optimized based on the airflow from the first outlet 402 such that the rate of heat dissipation from the electric motor 318 is enhanced. For example, the shape of the fins 610 and the spacing between adjacent fins 610 can be designed based on the airflow from the first outlet 402 of the duct 114. Thus, the electric motor 318 can have, for example, multiple circular fins, multiple longitudinal fins, or multiple circular and longitudinal fins, or spiral fins around the circumference of the electric motor 318.

[0067] Similarly, multiple fins 906 may be provided on the controller 322 to facilitate faster heat dissipation from the controller 322. Additionally, the shape of the fins 906 and the spacing between adjacent fins 906 of the controller 322 may depend on the airflow from the second outlet 502. In one example, the fins 906 of the controller 322 may be longitudinal.

[0068] FIG. 10 shows an exploded view of floor plate attachment 312, floor plate structure 310, and duct 114 from EV 100, according to an embodiment of the present invention.

[0069] In one example, to facilitate coupling of the floor plate attachment 312 to the frame 101 at the front portion 102 (not shown in FIG. 10), the frame 101 can include a first gusset 1002 on the left hand side 212 and a second gusset 1004 on the right hand side 214. The first gusset 1002 and the second gusset 1004 can be coupled to the first frame member 304 and the second frame member 306, respectively (not shown in FIG. 10), for example, and can extend rearward. In some examples, the first gusset 1002 and the second gusset 1004 can be integral with the first frame member 304 and the second frame member 306. Additionally, the first gusset 1002 can have a fifth bracket 1006, and the second gusset 1004 can have a sixth bracket (not shown in FIG. 10). The fifth bracket 1006 may be coupled to the first gusset 1002 or may be integral with the first gusset 1002, for example. Similarly, the sixth bracket may be coupled to the second gusset 1004 or may be integral with the second gusset 1004, for example. The floorboard attachment 312 may be coupled to the first gusset 1002 and the second gusset 1004 to facilitate attachment of the floorboard structure 310 to the frame 101. For example, the third bracket 902 may be coupled to the fifth bracket 1006, and the fourth bracket 904 may be coupled to the sixth bracket. In some examples, the front mounting support 604 of the duct 114, the third bracket 902, the fourth bracket, and the fifth bracket 1006 and the sixth bracket of the floorboard attachment 312 may be coupled together. This coupling may be facilitated by fasteners such as bolts and nuts.

[0070] Additionally, the duct 114 may be attached to the frame 101 at the rear portion 103 (not shown in FIG. 10) by utilizing a frame bracket 811 (not shown in FIG. 10). For example, the rear mounting support 608 on the duct 114 may be coupled to a frame bracket 811, which may be coupled to the frame 101. In particular, the frame bracket may be coupled to the underside of the third frame member 308.

[0071] In one example, the electric motor 318 may be coupled to the rear end 1008 of the floorboard structure 310. Additionally, the transmission system 112, which may be coupled to the electric motor 318, may include a coupling facility 1010 for coupling the transmission system 112 to the frame 101. For example, the coupling facility 1010 may be coupled to a rear suspension rod (not shown in FIG. 10), which may be coupled to the frame 101 at the rear end 1008 of the floorboard structure 310. This may facilitate support of the transmission system 112 on the frame 101.

[0072] 11a shows a perspective view of the EV 100, according to an embodiment of the present invention. In one example, the lower suspension bracket 216 may be curved to facilitate unobstructed airflow. For example, the lower suspension bracket 216 may be convex with respect to the gap 220. As such, the distance between the lower suspension bracket 216 and the front wheel fender 204 may vary along the width of the EV 100. As a result, the amount of airflow entering the duct 114 may be greater compared to a scenario in which the lower suspension bracket 216 is flat.

[0073] FIG. 11b shows a front view of the EV 100 according to an embodiment of the present invention. In one example, in addition to the lower suspension bracket 216 being curved, the nose wheel fender 204 may be curved. For example, the top surface 1102 of the nose wheel fender 204 may be convex with respect to the gap 220. Such a shape of the nose wheel fender 204 allows the nose wheel fender 204 to guide the air flowing in the front portion 102 (not shown in FIG. 11b) into the inlet 222 of the duct 114. As a result, the amount of air flowing into the duct 114 is increased compared to a scenario in which the nose wheel fender 204 has a flat shape. In the above example, the nose wheel fender 204 is described as having a convex shape with respect to the gap 220, but in some examples, the nose wheel fender 204 may be concave with respect to the gap 220. In some examples, the lower suspension bracket 216 may be flat and the nose wheel fender 204 may be curved.

[0074] In the examples above, the electric motor 318 is described as being open and exposed to the air, however, in some examples, the electric motor 318 may be housed within a housing, such as a cowl, as described below.

[0075] FIG. 12a shows a right side view of EV 100, according to an embodiment of the present invention.

[0076] The EV 100 may include a cowl 1202 that may surround and house the electric motor 318 to facilitate airflow around the electric motor 318. The cowl 1202 may be coupled to the duct 114. The cowl 1202 may include an inlet (not shown in FIG. 12a) that may be coupled to the first outlet 402 (not shown in FIG. 12a). Air from the duct 114 may be received at the inlet of the cowl 1202. The cowl 1202 may ensure that the received air is circulated over the entire exterior surface of the electric motor 318. This may ensure uniform cooling of the electric motor 318. Furthermore, cooling of the electric motor 318 may be more efficient compared to a scenario in which the electric motor 318 is not covered. Once the air has circulated around the electric motor 318, it may exit the cowl 1202 through the outlet 1204 of the cowl 1202.

[0077] In some examples, the distance between the cowl 1202 and the duct 114 may change due to movement of the EV 100. To ensure coupling of the cowl and the duct despite the variation in distance, a bellows may be used. For example, the cowl 1202 may be coupled to the duct 114 through a bellows.

[0078] FIG. 12b illustrates a perspective view of a combination of duct 114 and cowl 1202 of EV 100, according to an embodiment of the invention.

[0079] The duct 114 may be coupled to the cowl 1202 through a bellows 1208. The duct 114 may be coupled to the bellows 1208, and the bellows 1208 may be coupled to the cowl 1202. Thus, the first outlet 402 of the duct 114 (not shown in FIG. 12b) may be coupled to an inlet of the bellows 1208 (not shown in FIG. 12b), and the outlet of the bellows 1208 may be coupled to an inlet of the cowl 1202 (not shown in FIG. 12b).

[0080] The bellows 1208 may be a flexible portion that may expand or contract upon application of pressure. In one example, the bellows 1208 may expand and contract in response to a variation in the distance between the duct 114 and the cowl 1202, whereby the bellows 1208 may accommodate the movement of the cowl 1202 relative to the duct 114. For example, the bellows 1208 may expand in response to an increase in the distance between the duct 114 and the cowl 1202, and the bellows 1208 may contract in response to a decrease in the distance between the duct 114 and the cowl 1202. Thus, the bellows 1208 may ensure that air exiting the first outlet 402 is received at the inlet (not shown in FIG. 12b) of the cowl 1202. For example, the air exiting the first outlet 402 may flow through the bellows 1208 to reach the inlet of the cowl 1202.

[0081] In the above examples, the bellows 1208 is described as being coupled to the first outlet 402, but in some examples, the bellows 1208 may be coupled to the second outlet 502 of the duct 114.

[0082] FIG. 12c illustrates a top view of the combination of duct 114 and cowl 1202 as shown in FIG. 12b, according to an embodiment of the present invention.

[0083] In one example, to ensure air supply from the duct 114 to the cowl 1202. The bellows 1208 can form a snap fit with the inlet 1210 and the first outlet 402 of the cowl 1202, thereby ensuring no air leakage between the duct 114 and the cowl 1202. As will be appreciated, in the figures depicted herein, the outlet 1206 of the cowl 1202 (not shown in FIG. 12c) is located aft of the electric motor 318.

[0084] In the above examples, the duct 114 is described as having a single inlet. In some examples, to increase the amount of air supplied to cool the electric motor 318 and the controller 322 (not shown in FIG. 12c), the duct 114 can include multiple inlets, as described below.

[0085] FIG. 13a shows a top view of EV 100, according to an exemplary embodiment of the invention.

[0086] In this example, air may be admitted inside the EV 100 by providing an opening on the front panel 105. As an example, two openings may be provided on the front panel 105, such as an opening 1302 on the left hand side 212 (hereafter referred to as the "first opening") and an opening 1304 on the right hand side 214 (hereafter referred to as the "second opening"). The right hand side 214 may alternatively be referred to as the first side, and the left hand side 212 may alternatively be referred to as the second side. Thus, the second side is opposite to the first side. In an example, the EV 100 may include a duct 1306. To receive air from a first opening 1302 and a second opening 1304 on the front panel 105, the duct 1306 of the EV 100 may be provided with two front duct members, such as a first front duct member 1308 and a second front duct member 1310. Each front duct member may be disposed within an opening provided on the front panel 105.

[0087] The duct 1306 can extend from the front panel 105 towards the rear portion 103 of the EV 100. The first front duct member 1308 can extend rearwardly from a front face 1311 of the front panel 105 of the right hand side 214 through a first frame member 304 of the frame 101. The second front duct member 1310 can extend rearwardly from a front face 1311 of the front panel 105 of the left hand side 212 through a second frame member 306. The first front duct member 1308 and the second front duct member 1310 can be coupled to or integral with the front panel 105, for example.

[0088] Further, the duct 1306 can include a rear duct member 1312 that can be coupled to and extend rearwardly from a first front duct member 1308 and a second front duct member 1310. For example, an inlet (not shown in FIG. 13a) of the rear duct member 1312 can be coupled to an outlet (not shown in FIG. 12a) of the first front duct member 1308 and an outlet (not shown in FIG. 13a) of the second front duct member 1310. Thus, to facilitate coupling, the dimensions of the inlet of the rear duct member 1312 can be equal to or greater than the sum of the dimensions of the outlet of the first front duct member 1308 and the outlet of the second front duct member 1310. For example, the cross-sectional area of ​​the inlet of the rear duct member 1312 may be greater than or equal to the sum of the cross-sectional area of ​​the outlet of the first front duct member 1308 and the cross-sectional area of ​​the outlet of the second front duct member 1310 .

[0089] Similar to the duct 114, the duct 1306 can have multiple branches, such as a first branch and a second branch. In one example, the rear duct member 1312 can have a first branch 1314 and a second branch 1315. The first branch can correspond to the first branch 614, and the second branch can correspond to the second branch 616. Thus, the first branch 1314 can include a first outlet (not shown in FIG. 13a) for supplying air to the electric motor 318, and the second branch 1315 can include a second outlet (not shown in FIG. 13a) for supplying air to the controller 322.

[0090] Air from the front portion of the EV 100 enters the duct 1306 through an inlet 1316 of the first front duct member 1308 (hereinafter referred to as the "first inlet") and an inlet 1318 of the second front duct member 1310 (hereinafter referred to as the "second inlet"). Furthermore, the air entering through the first inlet 1316 and the second inlet 1318 may be combined together upon entering the rear duct member 1312. Furthermore, the air in the rear duct member 1312 may be supplied to the electric motor 318 through the first outlet and to the controller 322 through the second outlet. Thus, the heat-generating components may be prevented from overpressurizing.

[0091] FIG. 13b shows a right side view of EV 100, according to an embodiment of the present invention.

[0092] In one example, the first front duct member 1308 can extend through the first frame member 304 via an opening 1320 provided in the first frame member 304. Similarly, the second front duct member 1310 (not shown in FIG. 13b) can extend through an opening (not shown in FIG. 13b) provided in the second frame member 306 (not shown in FIG. 13b).

[0093] Furthermore, the arrangement of the electric motor 318 and the controller 322 allows the first front duct member 1308, the second front duct member 1310, and the rear duct member 1312 to move downwardly as they extend rearward to supply air to the electric motor 318 and the controller 322, whereby air from the duct 1306 is supplied to the electric motor 318 and the controller 322.

[0094] Similar to the duct 114, the shape of the duct 1306 may be designed in such a way that the duct 1306 passes through a portion of the cavity 316 that is not occupied by components such as the battery 104, interface box, etc. disposed in the cavity 316. For example, the portion of the duct 1306 that extends through the cavity 316 may be mounted on the floor plate structure 310 and positioned above all components that occupy the cavity 316. Thus, there is no need to redesign the components in the cavity 316, i.e., the components may be utilized without any dimensional changes and do not have to be relocated in the cavity 316.

[0095] In the implementation of the present invention, the shape of the duct can be designed while considering the dimensions of the components mounted on the floor plate structure and the arrangement of components such as batteries, interface boxes, etc. in the floor plate structure. Thus, the duct can be designed in such a way that it passes through a portion of the cavity that is not occupied by the components disposed in the cavity. For example, a portion of the duct that extends through the cavity can be disposed above all the components mounted on the floor plate structure and disposed in the cavity. Thus, the present subject matter does not need to redesign such components, i.e., such components can be utilized without any change in dimensions. Also, such components do not need to be disposed differently to accommodate the duct in the cavity.

[0096] The present invention allows for easy and efficient cooling of heat-generating components such as electric motors, controllers, etc. in an EV. Furthermore, because the present invention utilizes air flowing in the front portion of the EV to cool the heat-generating components, the present invention can prevent the use of additional power-consuming components such as cooling fans (which are driven by the electric motor or consume power from the EV's battery) to cool the electric motor. Thus, the present invention saves energy. As a result, the performance of the EV can be enhanced. By preventing the use of additional components such as cooling fans, the present subject matter also prevents noise generated by such components.

[0097] While the present invention has been described with reference to specific embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to those skilled in the art upon reference to the description of the invention.

Claims

1. An electric vehicle (EV) (100), a frame (101) extending rearward from a front portion (102) of the electric vehicle (100) toward a rear portion (103) of the electric vehicle (100); a floor plate structure (310) disposed below the frame (101) and supported by the frame (101); a battery (104) disposed within a cavity (316) defined between the floor structure (310) and the frame (101); a first heat generating component disposed within the rear portion (103) of the electric vehicle (100); a front wheel fender (204) disposed on the front portion (102); a duct (114, 1306) having a portion disposed above the battery (104), the duct (114, 1306) extending rearward from the front portion (102) of the electric vehicle (100) toward the first heat-generating component to direct air from the front portion (102) of the electric vehicle (100) to the first heat-generating component; a second heat generating component disposed within the cavity (316); The duct (114, 1306) an inlet (222) facing a front portion (102) of the electric vehicle (100) and configured to receive air from the front portion (102) of the electric vehicle (100); a first outlet (402) facing the first heat-generating component and configured to supply air to the first heat-generating component; a second outlet (502) facing the second heat generating component and configured to supply air to the second heat generating component; A suspension bracket (216) disposed above the front wheel fender (204); Equipped with the inlet (222) of the duct (114, 1306) faces a gap (220) between the front wheel fender (204) and the suspension bracket (216); the inlet (222) of the duct (114, 1306) is located above the front wheel fender (204); an upper surface (1102) of the front wheel fender (204) having one of a concave shape and a convex shape with respect to the gap (220); the shape of the upper surface (1102) of the nose wheel fender (204) is configured to guide air into the duct (114, 1306); An electric vehicle (100).

2. The electric vehicle (100) of claim 1, comprising a front wheel (106) disposed within a front portion (102) of the electric vehicle (100).

3. The electric vehicle (100) of claim 1, wherein the suspension bracket (216) is convex relative to the gap (220).

4. A front panel (105) is provided in a front portion (102) of the electric vehicle (100), and the duct (114, 1306) is A first front duct member (1308) extending rearward from a front surface (1311) of the front panel (105); and a rear duct member (1312) coupled to the first front duct member (1308) and extending rearwardly toward the first heat-generating component, the rear duct member comprising the portion of the duct (114, 1306) disposed above the battery (104).

5. the first front duct member (1308) extends rearwardly from the front surface (1311) of the front panel (105) at a first side (214) of the electric vehicle (100), and the ducts (114, 1306) are 5. The electric vehicle (100) of claim 4, comprising a second front duct member (1310) extending rearwardly from the front surface (1311) of the front panel (105) on a second side (212) of the electric vehicle (100), the second side (212) being opposite the first side (214), the second front duct member (1310) being coupled to the rear duct member (1312).

6. The rear duct member (1312) an inlet (1316) coupled to said first front duct member (1308) and said second front duct member (1310); and a first outlet facing said first heat generating component for supplying air to said first heat generating component.

7. 6. The electric vehicle of claim 5, wherein the rear duct member includes a second outlet facing a second heat-generating component disposed within the cavity, the second outlet configured to supply air to the second heat-generating component.

8. The electric vehicle (100) of claim 5, wherein the first front duct member (1308) and the second front duct member (1310) are integrated into the front panel (105).

9. a cowl (1202) surrounding the first heat generating component; The electric vehicle (100) of claim 1, wherein the duct (114, 1306) is coupled to the cowl to facilitate air flow around the first heat generating component.

10. 10. The electric vehicle (100) of claim 9, further comprising a bellows (1208) for preventing leakage of air from the duct (114, 1306) to the first heat generating component by accommodating movement of the cowl (1202) relative to the duct (114, 1306), an inlet of the bellows (1208) being coupled to the duct (114, 1306) and an outlet of the bellows (1208) being coupled to the cowl (1202).

11. The electric vehicle (100) of claim 1, wherein a load on the frame (101) is applied to the duct (114, 1306).

12. a floor plate mounting body (312) connected to the floor plate structure (310) and the frame (101); The top end (804) of the floor plate mounting body (312) is connected to the frame (101), and the bottom end (801) of the floor plate mounting body (312) is connected to the floor plate structure (310); The electric vehicle (100) of claim 1, wherein an inlet (222) of the duct (114, 1306) is coupled to the upper end (804) of the floor plate mounting (312).

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