Patent Publication Number: US-6991531-B2

Title: Vehicle and fresh air intake for a vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a division U.S. application Ser. No. 10/605,182 filed Sep. 12, 2003, which is hereby incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a vehicle and a vehicle fresh air intake that inhibits water ingestion. 
   2. Background Art 
   A vehicle may use ambient air from outside of the vehicle for a number of purposes. For example, vehicle radiators utilize ambient air to transfer heat from the engine coolant, to keep the engine from overheating. Outside air may also be mixed with fuel and supplied to the engine. Moreover, outside air may be utilized by heating, ventilation, and air conditioning systems (HVAC), which in turn maintain the climate of the vehicle passenger compartment. Of course, other vehicle systems may utilize outside air for a number of reasons, including the cooling of electrical components. When electrical components overheat, their performance may degrade or their life span may be compromised. Thus, adequate cooling for electrical components is an important consideration in vehicle design. 
   One example of a vehicle system that requires adequate cooling a bank of batteries used to power an electric vehicle. Other types of vehicle architectures—e.g., hybrid electric vehicles (HEV) and fuel cell vehicles—may similarly have power generating systems that emit large quantities of heat. Thus, it may be desirable to provide ambient air either directly to these systems, or to an HVAC that may further lower the air temperature to more effectively cool the vehicle system. One example of a fresh air intake used to take in ambient air to cool a bank of batteries in an electric vehicle is found in U.S. Pat. No. 5,392,873, issued to Masuyama et al. on Feb. 28, 1995. Masuyama et al. describes a structure for holding the batteries that includes an air intake passage. The air intake for the battery compartment is disposed beneath the vehicle, with an inlet facing upward toward the vehicle undercarriage. Because the inlet is disposed beneath the vehicle, liquid and solid debris from the road surface may enter the air intake. The air intake is provided with a chamber where liquid and other foreign material may be trapped prior to entering the battery compartment. The location of the air intake below the vehicle may increase the likelihood of taking in road debris. 
   Thus, there exists a need for a vehicle air intake configured to facilitate air transfer from an ambient environment outside the vehicle to a vehicle space, such that the air intake can be disposed on a portion of the vehicle away from the surface of the road, thereby reducing or eliminating the intake of road debris, while also inhibiting the transfer of water from the air intake to the vehicle space. 
   SUMMARY OF THE INVENTION 
   Therefore, an air intake for a vehicle configured to facilitate air transfer from an ambient environment outside the vehicle to a vehicle space is provided. The air intake includes a housing, a portion of which is configured for attachment to a vehicle window. The housing includes an inlet which is configured to be disposed along one edge of the window. 
   The invention also provides an air intake for a vehicle configured to facilitate air transfer from an ambient environment outside the vehicle to a vehicle space, while inhibiting liquid transfer from the ambient environment to the vehicle space. The air intake includes a housing having an inlet for receiving air from the ambient environment, and an outlet in communication with the inlet. The outlet is disposed in an upper portion of the housing and facilitates air transfer from the housing to the vehicle space. A first dam is disposed within the housing adjacent the inlet for preventing upward fluid flow from the inlet directly to the outlet, thereby inhibiting liquid flow through the outlet. 
   The invention further provides an air intake for a vehicle configured to facilitate air transfer from an ambient environment outside the vehicle to a vehicle space, while inhibiting liquid transfer from the ambient environment to the vehicle space. The air intake includes an inlet for receiving air from the ambient environment. A first chamber is adjacent the inlet and in communication with the inlet. The first chamber is partially defined by an upper boundary configured to prevent upward fluid flow out of the first chamber. A plurality of vanes are disposed adjacent to each other and in relation to the inlet such that the vanes direct the fluid flow from the inlet to the first chamber. A second chamber is adjacent the first chamber and has a common wall therebetween. The second chamber includes an upper portion and a lower portion; the lower portion is open to the first chamber. An outlet is in communication with the inlet. The outlet is disposed adjacent the second chamber upper portion, thereby facilitating air transfer from the second chamber to the vehicle space. 
   The invention also provides a vehicle having a window, a battery compartment, and an air intake configured to facilitate air transfer from an ambient environment outside the vehicle to the battery compartment, while inhibiting liquid transfer from the ambient environment to the battery compartment. The air intake includes a housing disposed adjacent the window. The housing includes an inlet disposed along one edge of the window for receiving air from the ambient environment. The housing also includes an outlet in communication with the inlet. The outlet is disposed in an upper portion of the housing and facilitates air transfer from the housing to the battery compartment. A first dam is disposed within the housing adjacent the inlet for preventing upward fluid flow from the inlet directly to the outlet, thereby inhibiting liquid flow through the outlet. 
   The above objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partial fragmentary side view of a vehicle including an air intake in accordance with the present invention; 
       FIG. 2  is a sectional view of the air intake shown in  FIG. 1 , taken through line  2 — 2 ; 
       FIG. 3  is a perspective view of a first portion of a housing of the air intake; 
       FIG. 4  is a perspective view of a portion of an alternative embodiment of the air intake shown in  FIGS. 1–3 ; 
       FIG. 5  is a partial fragmentary view of the air intake shown in  FIGS. 1–3  indicating the direction of air flow within the housing; 
       FIG. 6  is a perspective view of a second portion of the air intake housing; and 
       FIG. 7  is a partial fragmentary perspective view of a portion of a vehicle including an air intake, air conditioning system, and a battery compartment. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     FIG. 1  shows a portion of a vehicle  10  having an air intake  12  in accordance with the present invention. The air intake  12  is attached to a rear quarter window  14  of the vehicle  10 . Although the air intake  12  may be located adjacent the window  14 , it may be placed in other convenient locations, such as adjacent a vehicle body panel. 
   A sectional view of the air intake  12 , taken through section line  2 - 2  in  FIG. 1 , is shown in  FIG. 2 . As seen in  FIG. 2 , the air intake  12  includes a housing  16 , having a first portion  18  and a second portion  20 . The first portion  18  includes an inlet  22  that is open to an ambient environment outside the vehicle  10 . The second portion  20 , includes an outlet  24  in communication with the inlet  22 . As explained more fully below, ambient air from outside the vehicle enters the inlet  22 , flows through the housing  16 , and out of the outlet  24  to a vehicle space. In the embodiment shown in  FIGS. 1–2 , the inlet  22  is disposed adjacent one edge  26  of the window  14 . Within the housing  12 , there are first and second chambers  28 ,  30  having a wall  32  disposed therebetween. 
     FIG. 3  shows an isolated view of the first housing portion  18 . A plurality of vanes  34  are disposed adjacent to each other, and are disposed in relation to the inlet  22  such that they direct the flow of air from the inlet  22  into the first chamber  28 . Because the first and second housing portions  18 ,  20  cooperate to form the first and second chambers  28 ,  30  the first chamber  28  is not visible in  FIG. 3 . Directional arrows are shown in  FIG. 3  to indicate the general flow of air from the intake  22 . Although the vanes  34  shown in  FIG. 3  are relatively short and generally straight, it is contemplated that they may be configured differently to have a greater effect on the air flow. 
   For example, as seen in  FIG. 3 , the vanes  34  extend a relatively short distance into the first chamber  28 ; however, vanes may be configured to extend further into the first chamber, or alternatively, not at all. In addition to directing the air into the housing, vanes, such as the vanes  34 , may also breakup a water stream entering an air intake inlet. Vanes may be configured to provide an almost horizontal air flow into a housing, or may be angled to direct the air flow either up or down. As used here and throughout, directions such “up” and “down” refer to an air intake as installed in a vehicle. Still other vane configurations include curved vanes, or a combination of curved and straight portions. 
   One such example is illustrated in  FIG. 4 , which shows a portion of an air intake  36  having a plurality of vanes  38  disposed adjacent an inlet  40 , which is on the opposite side of the air intake  36  as shown in  FIG. 4 . As in the embodiment shown in  FIGS. 1–3 , the vanes  38  direct the flow of air from the inlet  40  into a first chamber  42 , only a portion of which is shown in  FIG. 4 . The vanes  38  increase in length as they near an upper portion  44  of the air intake  36 . In addition, the vanes  38  are curved so as to direct air flow from the inlet  40  in a generally downward direction. As explained more fully below, this helps inhibit water taken in from the ambient environment outside the vehicle from flowing into the vehicle space along with the air. 
   Returning to  FIG. 3 , it is seen that the vanes  34  are not curved like the vanes  38 , shown in the embodiment in  FIG. 4 . Despite this, at least some of the air flowing into the first chamber  28  of the air intake  12  will flow in a generally downward direction prior to entering the second chamber  30 ; this is illustrated in  FIG. 5 . The second chamber  30  includes a lower portion  46  that is open to the first chamber  28 . The second chamber  30  also includes an upper portion  48  which is adjacent the outlet  24 . Thus, as shown in the cutaway in  FIG. 5 , air from the first chamber  28  moves in a generally downward direction into the second chamber  30  before moving upward and through the outlet  24 . In this way, water which may enter the inlet  22  along with air from the ambient environment outside the vehicle, will be forced toward the bottom of the housing  16 , and will be inhibited from reaching the outlet  24  and flowing into a vehicle space. Water which is forced to the bottom of the housing  16  may exit the air intake  12  through the inlet  22 , or through a drain hole  49 , provided in the first housing portion  18 , see  FIG. 3 . 
   In order to direct the flow of air from the inlet  22  in a generally downward direction, fluid flow in the first chamber  28  is forced into the lower portion  46  of the second chamber  30 . This is accomplished by using a first dam  50 , shown in  FIG. 3 . The first dam  50  is an upper boundary which partially defines the first chamber  28 . The first dam  50  prevents the upward flow of fluid out of the first chamber  28 . The wall  32  forms a second dam which is adjacent to the inlet  22  and the first dam  50 . The first and second dams  50 ,  32  cooperate to force air from the inlet  22  in a generally unshaped flow path toward the outlet  24 , which separates water from the air. In the embodiment shown in  FIG. 3 , the first and second dams  50 ,  32  form a unitary blocking structure  52  that is integrally molded with the first housing portion  18 . 
   As seen in  FIG. 2 , the second dam  32 , and indeed the entire blocking structure  52 , extend from an inner surface  54  of the first housing portion  18  toward the second housing portion  20 . To help prevent fluid from flowing between the blocking structure  52  and the second housing portion  20 , a channel  56  is provided in the second housing portion  20 . As shown in  FIGS. 2 and 6 , the channel  56  is raised up from an inner surface  58  of the second housing portion  20 . Of course, a channel, such as the channel  56 , may be formed under the inner surface of a housing. A sealing material, such as foam, adhesive or the like may be disposed in the channel  56  to further prevent fluid from flowing between the blocking structure  52  and the second housing portion  20 . 
   Of course, a blocking structure, such as the blocking structure  52 , could be integral with the second housing portion  20 , or alternatively, it need not be integral with the housing at all. For example, individual dams could be manufactured separately and placed in grooves or channels prior to assembling the housing. The housing could be configured to accommodate a number of different dams and/or blocking structures, thereby allowing a degree of flexibility in the manufacturing of an air intake. As desired, different sealing materials could be used to help prevent fluid flow past the dams. 
   The housing  16  described herein, includes two housing portions  18 ,  20 . Of course, a housing, such as the housing  16 , may include a single portion, or more than two portions, as desired. With regard to the housing  16 , it is contemplated that the two portions  18 ,  20  may be made from different materials, and joined with a polymeric adhesive, such as urethane. To accommodate the use of a urethane adhesive, the second housing portion may be configured with standoff pins  59  to maintain a gap between the two housing portions  18 ,  20  after they are assembled. Alternatively, the housing portions  18 ,  20  may be joined with other types of adhesives, or even mechanical fasteners, such as screws or rivets. As seen in  FIG. 6 , the second housing portion  20  includes flanges  61 , which are used in conjunction with locating pins  63  on the first housing portion  18 , see  FIG. 3 . 
   The use of different materials for each housing portion may accommodate the different functions of the two housing portions  18 ,  20 . For example, the first housing portion  18 , has an outer surface  65  exposed to the ambient environment, see  FIG. 2 . In addition, the outer surface  65  is visible from the vehicle exterior, where it may be desirable to present an aesthetically pleasing appearance. Thus, an abrasion resistant polymer, such as a polycarbonate, which may also provide an appearance finish, may provide the desired combination of properties for the first housing portion  18 . 
   Unlike the aesthetic considerations which may be present for the material selection of the first housing portion  18 , different properties may be more important for the second housing portion  20 . For example, strength may be a primary consideration, since the second housing portion  20  is not visible from the vehicle exterior. Hence, an acrylonitrile butadiene styrene (ABS) or polypropylene (PP) may be well suited for the second housing portion  20 . Of course, the foregoing are merely examples of some of the materials from which the housing  16  may be made. Different considerations may be present for various embodiments of the present invention, and other polymers or even other classes of materials may be desired for a particular application. 
   As briefly discussed above, an air intake, such as the air intake  12 , may be used to transfer air from an ambient environment outside a vehicle to a vehicle space. The air may flow directly through the air intake and into the vehicle space, or it may flow into some type of air conditioning system prior to reaching the vehicle space. One such air conditioning system is described in copending U.S. patent application Ser. No. 10/605,179, entitled “Cooling System for a Vehicle Battery”, filed on Sep. 12, 2003, and hereby incorporated herein by reference.  FIG. 7  shows an interior portion  60  of the vehicle  10 . The outlet  24  of the air intake  12  is attached to a duct  62  which transfers air from the outlet  24  to an air conditioning system  64 . 
   The air conditioning system  64  draws fresh air in through the inlet  22  with a blower fan, and outputs cooled air through a duct  66  and into a battery compartment  68 . Supplying the battery compartment  68  with cool air from the air conditioning system  64 , will help cool battery assembly  70 , thereby helping to extend its life. Of course, air taken in from an air intake, such as the air intake  12 , may be routed to any desired vehicle space, or into another type of air conditioning system—e.g., an air conditioning system used to cool the vehicle passenger compartment. An example of an air conditioning system that can be used to cool both a battery compartment and a passenger compartment is described in copending U.S. patent application Ser. No. 10/605,181, entitled “Vehicle Cooling System”, filed on Sep. 12, 2003, and hereby incorporated herein by reference. 
   As described above, the air intake  12  helps to inhibit water taken in from the ambient environment outside the vehicle  10  from flowing through the outlet  24 . Thus, the air conditioning system  64  receives little or no water from the air intake  12 . In addition, because the air intake  12  may be disposed high up on a vehicle away from the surface of the road, it is unlikely that road debris or other solid matter will enter the inlet  22 . If, however, some solid matter does enter the air intake  12 , it will be forced downward with the air flow toward the bottom of the housing  16 , where it is free to exit the air intake  12  through the inlet  22 . Although it may be unlikely that any solid matter would be carried upward and out of the outlet  24 , additional protection is easily added to the air intake  12 . If desired, one or more air-permeable barriers, such as screens, may be added to the air intake  12  to prevent solids, and to some extent liquids, from reaching the vehicle space. For example, returning to  FIG. 2 , screens  72 ,  74  are shown adjacent the inlet  22  and the outlet  24 , respectively. Of course, screens, or other air-permeable barriers, may be placed at different locations on or in the air intake  12  as desired. 
   While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.