Patent Abstract:
A vehicle includes a floor, a seat including a back, and a traction battery module located behind the seat. The seat and floor form an air passageway, underneath the seat, from a cabin to the traction battery module. The vehicle also includes a plenum disposed between the air passageway and fraction battery module, and a sealing member fixed to the plenum and configured to engage the back to form a substantially airtight seal therebetween.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of application Ser. No. 11/755,296, filed May 30, 2007, the disclosure of which is hereby incorporated in its entirety by reference herein. 
     
    
     TECHNICAL FIELD 
       [0002]    The disclosure relates to ductless cooling systems for vehicle power storage units. 
       BACKGROUND 
       [0003]    A battery for a Hybrid Electric Vehicle (HEV) may require cooling during usage. Some HEVs use chilled air from a dedicated air conditioning unit. Other HEVs use fresh air from outside the vehicle. Still other HEVs use air from the cabin via a duct located on a side of the rear seat or in a package tray. 
       SUMMARY 
       [0004]    Certain embodiments may take the form of a system for delivering air from a vehicle cabin to a vehicle power storage unit. The system includes a floor, a vehicle seat, and a power storage unit to provide power to move the vehicle. The vehicle seat and floor define an air passageway, underneath the vehicle seat, from the vehicle cabin to the power storage unit. 
         [0005]    While exemplary embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a front perspective view, partially exploded, of portions of a cooling system for a traction battery module of a vehicle, and shows the pathway for air, indicated by dotted line arrow, from the vehicle cabin to the traction battery module. 
           [0007]      FIG. 2  is a block diagram of the cooling system of  FIG. 1  and shows the pathway for air, indicated by arrow, from the vehicle cabin to the trunk. 
           [0008]      FIG. 3  is a front perspective view, in cross-section, of portions of the cooling system of  FIG. 1  taken along section line  3 - 3  of  FIG. 1 , and shows the pathway for air, indicated by arrow, from the vehicle cabin, through the enclosure, inlet plenum, and traction battery module, to the trunk. 
           [0009]      FIG. 4  is a rear perspective view of portions of the cooling system of  FIG. 1 , and shows air, indicated by arrow, exiting the inlet plenum. 
           [0010]      FIG. 5  is a front perspective view of the seal of  FIG. 4  associated with the inlet plenum. 
           [0011]      FIG. 6  is a top perspective view of the support of the rear seat of  FIG. 1 . 
           [0012]      FIG. 7  is a bottom perspective view of the support of  FIG. 6  and shows portions of the enclosure, as indicated by speckling, defined by the support. 
           [0013]      FIG. 8A  is a side elevation view of the rear seat, seal, and inlet plenum of  FIG. 1 , and shows the seat in the upright position and sealed with the seal. 
           [0014]      FIG. 8B  is another side elevation view of the rear seat, seal, and inlet plenum of  FIG. 8A , and shows the rear seat in the folded position and not sealed with the seal. 
           [0015]      FIG. 8C  is a side elevation view of an alternative embodiment of the rear seat, seal, and inlet plenum, and shows the rear seat in the folded position and sealed with the seal. 
           [0016]      FIG. 8D  is a side elevation view of another alternative embodiment of the rear seat and inlet plenum, and shows the rear seat in the folded position and attached with the inlet plenum. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    A dedicated air conditioning unit to cool a traction battery may be expensive and reduce cargo volume. Introducing fresh air from outside a vehicle to cool a traction battery may present water and dust management issues. Using cabin air to cool a fraction battery delivered via ducts located on the side of rear seats may present space, ingress/egress, complexity, and occupant comfort issues. Similarly, ducts passing through a package tray may pass directly under a rear window glass and may be subject to preheating from a solar load. Additionally, ducts require clearances and reduce volume due to duct thickness. 
         [0018]    Some embodiments of the invention provide a ductless cooling system that draws air from the vehicle cabin to cool the battery. A physical inlet duct is not required. Instead, the rear seat and the floor form a chamber for the inlet air stream. The air is drawn underneath the rear seat, through an inlet plenum connecting the seat to the battery, to cool the cells. The warm air, after the heat exchange, is then drawn by a fan and discharged from the battery system to an open volume such as the vehicle trunk, vehicle outside, or other desirable space. 
         [0019]    The inlet plenum may impede recirculation of air from the trunk to the inlet of the air stream. Sealing features, such as an oversized foam seal disposed along the interface between the inlet plenum and the seat back, may allow simple seat assembly and be designed to work, and seal, with a foldable back. As such, portions of the foldable seat may be contoured, at the interface with the inlet plenum, to promote such sealing. For example, a parabolic or circular interface seat surface may be used such that each radius in the seat curvature separates quickly from the inlet plenum to minimize the shear between the foam and back as the seat is rotated. 
         [0020]    Seat cushions may taper at the interface with the seat back. The tapers may provide a seal to reduce air leakage from the sides of the seat and also force the air to come from the front of the seat. 
         [0021]    The ductless cooling system may support the seat cushion without affecting the seat comfort or H-point. The system may provide an air space underneath the seat, an air inlet to allow air to enter the air space from the cabin, proper support that ensures customer comfort when seated, and a dust/moisture filter or screen mesh to reduce the amount of dust/moisture entering the air space. 
         [0022]    The support for the cushion may be provided via a seat cushion wire structure, a bridge form, plastic or metal, to transfer the cushion loads to the floor, or support ribs that pass through an air cavity and serve as flow guiding vanes. 
         [0023]      FIG. 1  is a front perspective view, partially exploded, of portions of cooling system  10  for traction battery module  12  of vehicle  14  showing the path of air, indicated by dotted line arrow, from the vehicle cabin to traction battery module  12 . Portions of floor  16  and rear seat  18  form enclosure  20  under rear seat  18 . Enclosure  20  provides an air passageway for air to travel, as indicated by dotted line arrow, from the vehicle cabin to traction battery module  12 . As explained below, air travels under seat  18  and into traction battery module  12 . 
         [0024]      FIG. 2  is a block diagram of cooling system  10  of  FIG. 1  showing the pathway for air, indicated by arrow, from the vehicle cabin to trunk  26 . Air travels first through inlet grille  22 , which obscures occupant view of dust filter  28  and enclosure  20 , and into enclosure  20  under seat  18 . Inlet plenum  24  directs the air from enclosure  20  to traction battery module  12  where it cools the traction battery. Outlet plenum  30  directs the air from traction battery module  12  to fan  32 . Fan  32  blows the air into trunk  26 . 
         [0025]    In some embodiments fan  32  may be used to pull air from the vehicle cabin to traction battery module  12  through enclosure  20 . Fan  32  may be located before or after traction battery module  12 . Fan  32  may also be located in traction battery module  12 . In other embodiments fan  32  may be absent. In still other embodiments, other portions of system  10 , e.g., dust filter  28 , plenums  24 ,  30 , etc., may be absent. 
         [0026]      FIG. 3  is a front perspective view, in cross-section, of portions of cooling system  10  of  FIG. 1  taken along section line  3 - 3  of  FIG. 1  showing the pathway for air, indicated by arrow, from the vehicle cabin, through enclosure  20 , inlet plenum  24 , and traction battery module  12 , to trunk  26 . As discussed above, air may be pulled or pushed from the vehicle cabin by fan  32  ( FIG. 2 ), if present and depending on its location, or air may be forced into cooling system  10  by a vehicle climate control system (not shown). 
         [0027]      FIG. 4  is a rear perspective view of portions of cooling system  10  showing air, indicated by arrow, exiting inlet plenum  24 . Inlet plenum  24  includes seal  35 . Seal  35  may be a soft, flexible material, e.g., foam, capable of producing a substantially airtight seal between inlet  24  and its interfacing parts. In the embodiment of  FIG. 4 , seat  18  is in the upright position and inlet plenum  24  seals against rear seat  18 . Inlet plenum  24  also seals against floor  16  via seal  35 . As such, a substantially air tight seal exists between enclosure  20  and inlet plenum  24 . Inlet plenum is mechanically connected, e.g., bolted, with traction battery module  12  such that a generally air tight seal exists between inlet plenum  24  and traction battery module  12 . In other embodiments, inlet plenum  24  may be attached with traction battery module  12  in any desired fashion, e.g., adhered, bonded. A foam seal may also be placed between inlet plenum  24  and traction battery module  12 . 
         [0028]      FIG. 5  is a front perspective view of seal  35  of  FIG. 4  associated with inlet plenum  24 . In other embodiments, seal  35  may have a different shape or design depending on the shape or design of inlet plenum  24 , if present, and its interfacing parts. 
         [0029]      FIG. 6  is a top perspective view of support  34  of rear seat  18  of  FIG. 1 . Support  34  forms the understructure for rear seat  18  on which cushion material (not shown) may be placed. Support  34  includes opening  36  which provides the inlet for air from the vehicle cabin into enclosure  20 . Inlet grille  22  and dust filter  28  ( FIG. 2 ) cover opening  36  to prevent unobstructed flow of air from the vehicle cabin to enclosure  20 . Support  34  may be made, formed, or molded in any conventional fashion. 
         [0030]      FIG. 7  is a bottom perspective view of support  34  of  FIG. 6  showing portions of enclosure  20 , as indicated by speckling, defined by support  34 . The sides of enclosure  20  are defined by air passage walls  38 ,  40 . The top of enclosure  20  is defined by upper air passage surface  42 . In the embodiment of  FIG. 7 , air passage walls  38 ,  40 , upper air passage surface  42 , and floor  16  cooperate to define enclosure  20  under rear seat  18 . Divider  44  transfers occupant loads from rear seat  18  to floor  16  as well as promotes the desired air flow through enclosure  20 . Support structures  46  within enclosure  20 , likewise, transfer occupant loads from rear seat  18  to floor  16  as well as promote the desired air flow through enclosure  20 . Support structures  46  outside of enclosure  20  transfer occupant loads from rear seat  18  to floor  16 . Support structures  46 , in the embodiment of  FIG. 7 , have a conical shape. In other embodiments, support structures  46  may have any desired shape, e.g., rib, pillar, etc. 
         [0031]      FIG. 8A  is a side elevation view of rear seat  18  having a parabolic shape, seal  35 , and inlet plenum  24  showing seat  18  in the upright position. As described above, if seat  18  is in the upright position, seal  35  of inlet plenum  24  seals against rear seat  18 . 
         [0032]      FIG. 8B  is another side elevation view of rear seat  18 , seal  35 , and inlet plenum  24  of  FIG. 8A  showing rear seat  18  in the folded position. In the folded position, rear seat  18  does not seal against seal  35  of inlet plenum  24 . As such, air from the vehicle cabin may flow directly into inlet plenum  24  and thus traction battery module  12 . 
         [0033]      FIG. 8C  is side elevation view of an alternative embodiment of rear seat  118 , seal  135 , and inlet plenum  124  showing rear seat  118  in the folded position. Portions of rear seat  118  have a circular shape with the center of rotation for the seat back being the center of the circular shape such that if rear seat  118  is in the folded position, seal  135  of inlet plenum  124  seals against rear seat  118 . 
         [0034]      FIG. 8D  is a side elevation view of another alternative embodiment of rear seat  218  and inlet plenum  224  showing rear seat  218  in the folded position and attached, e.g., bolted, with inlet plenum  224 . Inlet plenum  224  has an accordion-like configuration that permits it to extend and retract as rear seat  218  moves between the upright and stowed positions while maintaining its seal with rear seat  218 . 
         [0035]    Certain embodiments may enable cabin air to be delivered to a battery system, reduce cost and weight required to route air to a battery system, and reduce the number of parts and labor associated with assembly processes. Certain embodiments may also occupy less volume resulting in increased room for airflow and seat cushions and are robust to floor dimensional variation caused by, for example, the presence of dampening materials. 
         [0036]    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.

Technology Classification (CPC): 1