Air-Cooled Battery Duct Structure for Cabin Heat and Noise Isolation

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Solution Overview

Problem

Existing air-cooled battery systems in vehicles generate noise, vibration, and heat that are delivered to the passenger compartment, complicating vehicle design and compromising passenger comfort.

Innovation Solution

A duct structure comprising a duct and a carpet pad with guide passages that directs heated air from the battery assembly to the edge of the vehicle, using foam and fabric materials to minimize noise, vibration, and heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the outlet duct is mounted on the floor to discharge heated air, then the battery cooling function is achieved, but noise and vibration are generated and heat is delivered to passengers

Engineering Contradiction:

Improvebattery temperatureVSAvoidnoise, vibration, and heat affecting passengers

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a carpet pad as an intermediary component between the outlet duct and the passenger compartment. This carpet pad absorbs and dampens noise and vibration from the discharged air, while its thermal insulation properties prevent heat from reaching passengers. The intermediary structure allows the exhaust function to be maintained while blocking harmful effects.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent utilizes the existing carpet pad in the vehicle interior, which is a standard, cost-effective component already present in most vehicles. By repurposing this existing element for noise and heat isolation, the solution avoids adding expensive specialized materials while achieving the desired isolation效果.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If seat rails and vehicle body members are arranged to ensure vehicle stiffness, then structural strength is improved, but it becomes difficult to create a structure to prevent noise, vibration, and heat from reaching passengers

Engineering Contradiction:

Improvevehicle stiffnessVSAvoiddifficulty in creating noise and heat isolation structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The carpet pad serves multiple functions simultaneously: it provides noise and vibration dampening, thermal insulation, and maintains compatibility with the existing seat rail and body member layout. This multi-functional approach allows the structure to maintain vehicle stiffness while achieving noise and heat isolation without requiring complex redesign.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If the duct guides air to the edge of the vehicle through the carpet pad, then noise, vibration, and heat are prevented from reaching passengers, but the duct structure becomes more complex

Engineering Contradiction:

Improvepassenger comfortVSAvoidduct structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the air guidance function with the existing carpet pad structure. Instead of creating a separate complex isolation structure, the duct is integrated with the carpet pad, allowing the same component to serve both as a structural element and as a noise/heat isolation medium. This reduces overall system complexity while achieving the desired protection.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The duct structure effectively prevents noise, vibration, and heat from reaching the passenger compartment, enhancing vehicle comfort and improving battery cooling performance.

Implementation Method 1

A duct structure for an air-cooled battery may include a duct configured to guide air flowing out from a battery assembly disposed under a floor of a vehicle in a longitudinal direction of the vehicle; and a carpet pad covering the duct

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 2

The carpet pad may be made of a foam material

Methodology Applied

Scientific EffectViscous damping: Viscous Damping

Implementation Method 3

The guide passage may have a groove-shaped cross section recessed from a bottom surface of the carpet pad toward a top surface of the carpet pad

Methodology Applied

Scientific EffectFluid flow guidance:

Data Source

PatentUS20250372763A1Duct structure for an air-cooled battery

Publication Date: 2025.12.04 HYUNDAI MOTOR CO LTD

AI summary

A duct structure for an air-cooled battery including a duct configured to guide air flowing out from a battery assembly disposed under a floor of a vehicle in a longitudinal direction of the vehicle, and a carpet pad covering the duct, where the carpet pad includes a guide passage extending from a portion of the carpet pad adjacent to the duct to a side edge of the floor.