Vehicle Side-Rail Air Duct Layout for Compact EV Cooling
Solution Overview
Problem
Electric and partially electric vehicles face challenges with cooling systems due to coolant demand from multiple components, leading to increased power consumption and packaging size, particularly in vehicles with internal combustion engines where ambient air cooling is limited by high air temperatures.
Innovation Solution
A system incorporating a passage from the front wheel well to the rear wheel well that receives ambient air, with a fan positioned upstream of heat exchangers, allowing air to flow along the vehicle's side rail and expel it normal to the direction of travel, reducing the need for liquid coolant and optimizing packaging by using differently shaped air ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid coolant systems are used to cool multiple components, then cooling effectiveness is improved, but packaging size and power consumption increase
Solution Approach 1:
The patent extracts the cooling function from a centralized liquid coolant system and implements separate air cooling passages for each heat-generating component (motor, inverter, charger). This eliminates the need for complex liquid cooling infrastructure while maintaining effective cooling, thereby reducing packaging size without sacrificing cooling performance.
Solution Approach 2:
The patent transitions from liquid coolant hydraulic system to pneumatic air cooling system. By using ambient air or vehicle cabin air as the cooling medium through dedicated passages, the system achieves effective heat dissipation without pumps, radiators, and coolant reservoirs, significantly reducing packaging requirements.
2Temperature
If liquid coolant systems are used to cool multiple components, then cooling effectiveness is improved, but power consumption increases
Solution Approach 1:
The patent removes the energy-consuming liquid pumping system and replaces it with passive air flow paths. Each component has its own air passage that可以利用 vehicle motion (ram air effect) or small fans, dramatically reducing the electrical power required for cooling operations while maintaining adequate temperature control.
Solution Approach 2:
The air cooling passages are designed to utilize the vehicle's own motion and ambient air flow to provide cooling. The passages are positioned to capture ram air during vehicle operation, and the system self-regulates airflow without requiring external power input for pumps or complex flow control mechanisms.
3Temperature
If air ducts are configured to receive ram air from the front end, then cooling is provided, but packaging size increases for mid-ship components
Solution Approach 1:
The patent implements localized air cooling passages positioned adjacent to each heat-generating component rather than using a centralized front-end air intake system. This localizes the cooling function at the point of heat generation, eliminating the need for long air ducts and large packaging space while providing effective cooling where it is most needed.
Solution Approach 2:
The patent repositions the air cooling passages from a front-end longitudinal configuration to a lateral/distributed configuration along the vehicle side. The passages extend from the front wheel well laterally toward the rear, utilizing the side profile space rather than front-end volume, thereby reducing packaging requirements while maintaining cooling capability.
4Volume of stationary object
If differently shaped air ducts are used to draw air closer to the vehicle mid-ship, then packaging size is reduced, but air intake temperature may increase
Solution Approach 1:
The patent positions air intake openings at the front wheel well area, which is a localized region away from the hot exhaust and engine bay. By drawing air from this specific cooler location and delivering it directly to adjacent components, the system achieves both compact packaging and adequate cooling without drawing hot air from the front end.
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
This configuration reduces the packaging size and power consumption of cooling systems by utilizing ambient air effectively, enhancing cooling efficiency for components like battery packs and electric motors while maintaining regenerative braking capabilities without the need for customized components.
Implementation Method 1
The passage may receive ambient air at the inlet and flow ambient air along a lower lateral side rail of the vehicle toward the outlet
Implementation Method 2
with a fan positioned upstream of heat exchangers
Implementation Method 3
flow ambient air along a lower lateral side rail of the vehicle toward the outlet
Data Source
AI summary
Systems for a vehicle air duct including a passage, the passage including an inlet at a downstream portion of a front wheel well of the vehicle and an outlet upstream of a rear wheel well of the vehicle.