Description:[001] The invention comprises an improvement in, or a modification of, the invention claimed in the specification of the main patent applied for “HEAT MANAGEMENT SYSTEM FOR A TWO WHEELED VEHICLE” having application number 201621011002 filed on 30/03/2016.
FIELD OF INVENTION
[002] The present invention relates to a heat management system suitable for a two wheeled automotive vehicle, more particularly to a vehicle wherein the prime mover (engine, battery etc.) is fully or partially accommodated in a vehicular structure such as a bonnet.
BACKGROUND
[003] Running of a vehicle’s prime mover (for example engine or battery etc.) for a long period of time increases its temperature and creates a hot environment around it. So, the prime mover requires constant cooling.
[004] For example, liquid cooled engines are provided with an arrangement for passing cooled liquid around the engine thus maintaining temperature of engine within a safe operating temperature range. However, the liquid cooled engines require space for cooling arrangements, and also consume energy through running of a pump for the cooling liquid. Such cooling arrangements also make the vehicle relatively bulky.
Air cooled engines or battery modules are cooled by flow of atmospheric air over engine surfaces to dissipate the heat by directing hot air away from the engine/ battery module. Air cooling is also useful for cooling of prime mover (battery module or electric motor or both), in electric vehicles (EV).
[005] But, when the prime mover is disposed inside a space of a vehicular structure, for example in a bonnet compartment of a vehicle, the air cooling is not effective as the vehicular structure creates a barrier between atmospheric cooling air and the prime mover.
[006] Thus, when the prime mover of EV, as discussed above, is mounted in a vehicular structure having a battery compartment or space covered on all sides by body panels especially from the front side, such as in a scooter-type vehicle; management of the heat generated by operation of prime mover becomes a major concern. In such a vehicular structure, insufficient air flow reaches the battery module and/or electric motor for required cooling. Further, removal of heated air from the space around the prime mover is also a challenge. Both these phenomena may lead to accumulation of heat in the compartment of prime mover, causing serious damage to the performance of the prime mover as well as electronic elements of the control system. Further, when the rider/pillion rider sitting location is above the compartment of prime mover, the heat may be dissipated to a rider’s/pillion rider’s body. This causes at least discomfort, but also the possibility of injury.
[007] The cooling air requirement is usually addressed by taking in so-called “ram” air through apertures provided in the front panel of the scooter, which is allowed to pass through a closed floorboard volume towards the prime mover compartment. This closed floorboard volume is formed between the floorboard on which the rider’s feet rest and a lower cover panel, and parts of the vehicle frame, electrical components, etc. lie within this volume). However, air flowing through the floorboard volume is dampened and diverted by the scooter frame and electrical components in its path away from the engine compartment or battery module (in EV). Moreover, air which does not enter this enclosed volume through the apertures available in the front panel, dashes against the front panel, scatters and escapes underneath and along the sides of the vehicle body. A low pressure area is also formed between the front fender and the front panel, which leads to drop in intensity of air flowing in through the apertures, thus leading to drop in available cooling air volume and cooling efficiency.
OBJECTIVES OF INVENTION
[008] Accordingly, one of the objectives of the invention is to provide a heat management system including fan/s in a heat management structure to enhance efficiency of air cooling of a vehicle prime mover (such as battery etc.,).
[009] Yet another objective of invention is to provide a heat management system which is uncomplicated in construction and provides high ram air with improved cooling efficiency.
SUMMARY OF INVENTION
[0010] The present invention provides a heat management system for air cooling of a battery module of a two wheeled vehicle that includes a structure. In an exemplary embodiment the structure has a first portion and a second base portion. The first portion includes a substantially vertically extending wall at one end configured to gather and direct cooling air through it to form a first portion of cooling air for the battery module. The second base portion configured to gather and direct cooling air through it to form a second portion of cooling air for the battery module. A plurality of fan or blower induce air cooling flow to the heat management system. In an exemplary embodiment, a fan is disposed at least partially below the battery module to induce air.
[0011] In another exemplary embodiment, an additional second fan is disposed above the battery module.
[0012] In further another an exemplary embodiment, an fan is directly mounted with the battery module at a proximate end of the battery module.
[0013] In an exemplary embodiment, the first portion of the structure includes at least one aperture through which cooling ram air enter into the heat management system.
[0014] In an exemplary embodiment, the first portion in the form of the substantially vertically extending wall has a shape directed to collection of cooling air for directing through the aperture/s.
[0015] In an exemplary embodiment, the first portion have the shape in the form of a recess or concavity with aperture/s rearward from edges of a wall of the first portion.
[0016] In an exemplary embodiment, shape of the aperture/s is preferably non-circular.
[0017] In an exemplary embodiment, the first portion of cooling air that pass through the first portion is divided into a plurality of corresponding side channels forming part of a floorboard structure.
[0018] In an exemplary embodiment, the second base portion is configured with a channel and a scoop arrangement on its lower surface to gather and direct the second portion of cooling air towards the battery module.
[0019] In an exemplary embodiment, an entry portion to the channel have an upwardly curved shape to guide an airflow through the second base portion.
[0020] In an exemplary embodiment, a plurality of deflectors at a rear end of the side channels guide cooling air towards the battery module.
[0021] In an exemplary embodiment, the entry portion forms part of a transition between the first portion and the second base portion and the entry portion is located to collect air which cannot pass through the aperture/s).
[0022] In an exemplary embodiment, the plurality of deflectors and a plurality of baffles at a rear end of the second base portion guide cooling air towards the battery module.
[0023] In an exemplary embodiment, the first portion forms a shield for a rider and accommodation for the rider’s legs and feet.
[0024] In an exemplary embodiment, the heat management system includes a platform for the rider’s feet.
[0025] In an exemplary embodiment, the heat management system further includes a plenum portion for combining cooling air from the first portion of the heat management structure and cooling air from the second base portion gathered by the structure and using said combined cooling air flow to cool the prime mover.
[0026] In an exemplary embodiment, the prime mover is enclosed by a vehicular structure provided with an exhaust system to enable air heated during the prime mover cooling process to be exhausted during static and dynamic vehicle conditions.
[0027] In an exemplary embodiment, a rear surface of the vehicular structure includes a grille arrangement that assists in exhausting hot air trapped inside the vehicular structure.
[0028] In an exemplary embodiment, the two wheeled vehicle includes a storage box mounted under a seat and indirect openings by a plurality of cut outs are located in a top most portion of a under seat cover, for exhausting heated air.
[0029] In an exemplary embodiment, the cut-outs have covers mounted over them such that sufficient gap is left between the cut-outs and the cover to allow heated air to escape into atmosphere.
[0030] The heat management structure may include other features than described above. A vehicle including a heat management system as above described forms another embodiment of the present invention. Such vehicles would typically include motorcycle type vehicles such as scooters.

SHORT DESCRIPTION OF DRAWINGS
[0031] Figure 1 is a schematic of a heat management system including battery module as a prime mover in scooter-type electric vehicle.
[0032] Figure 2A is a first bottom orthogonal view of the floorboard structure included within the scooter-type motorcycle shown in Figures 1 and forming part of the heat management system.
[0033] Figure 2B is a second orthogonal view of the floorboard structure shown in Figure 2A.
[0034] Figure 2C is a top view of the floorboard structure shown in Figures 2A, and 2B.
[0035] Figure 2D is a bottom view of the floorboard structure shown in Figures 2A to 2C and taken in a different orientation to Figure 3A.
[0036] Figure 2E is an exploded bottom view of the floorboard structure shown in Figures 2A to 2D.
[0037] Figure 2F is an orthogonal view of the floorboard structure shown in Figures 2A to 2E, along with a platform for rider’s feet.
[0038] Figure 3A to 3D are schematic of ram air circulation by a heat management system towards the battery module from a front panel and a floorboard structure of scooter-type electric vehicle, in accordance with an exemplary embodiment of present invention.
[0039] Figure 3E illustrates a storage box mounted under seat and indirect openings or vents for exhausting such heated air, in accordance with an exemplary embodiment of present invention.

[0040] Figure 4A is a schematic view of exemplary first embodiment of present invention where a heat management system including a fan used for induced cooling of prime mover.
[0041] Figure 4B is a schematic view of exemplary first embodiment of present invention, i.e., the heat management system of Figure 4A with an additional fan used for induced cooling of prime mover.
[0042] Figure 5A is a schematic view of exemplary second embodiment of present invention where a heat management system including a fan used for induced cooling of prime mover (battery module).
[0043] Figure 5B is a schematic view of exemplary second embodiment of present invention, i.e., the heat management system of Figure 5A with a fan integrally mounted at front of the prime mover (battery module) to induce cooling air.
DESCRIPTION OF PREFERRED EMBODIMENT
[0044] The present invention provides one or more fan mounting in a heat management system for air cooling of a prime mover of a scooter-type two wheeled electric vehicle (2W EV). The heat management system includes a structure that has a first portion including a vertically extending wall at one end configured to gather and direct cooling air through it to form a first portion of cooling air for the prime mover; and a second base portion configured to gather and direct cooling air through it to form a second portion of cooling air for the prime mover.
[0045] The prime mover amenable to air cooling is typically a battery module, electric motor, or both, or similar prime movers. The battery module includes one or more batteries. Cooling air supplied by the heat management system to the battery module is atmospheric air which is inducted into the heat management system as the vehicle is operated. In the present invention, one or more fans are included within the structure to induce air cooling flows to the heat management system, if required.
[0046] The one or more fans are located around the prime mover, such that the cooling air circulation is significantly increased to amplify cooling efficiency of the heat management system. The one or more fans arrangement in an exemplary embodiment are secured either on vehicle frame or prime mover housing body integrally or by bolting/welding methods. Description of preferred but non-limiting embodiments of the heat management system of the present invention will now follow with reference to the drawings.
[0047] Referring first to Figure 1, illustrating an exemplary embodiment of two-wheeled (2W) electric vehicle (EV) 100 having a frame 102 including a head pipe 103, a body frame 106 and rear frame 108. Below seat area of the two-wheeled EV, the frame 102 accommodates a battery module 24. The battery module 24 is mounted on the body frame 106.
[0048] During operation of the 2W EV 100, the battery module 24 gets heated and requires cooling for efficient operation. This is achieved by directing the ram air to flow over the battery surface through the air path created by a front panel 232 and a floorboard structure 200, the ram air flow is a described in figures 3A to 3D.
[0049] The 2W EV 100 includes a heat management system 10 for air cooling of its battery module 24 having, as shown in detail in Figures 2A to 2F, the structure 200 that has a first portion 220 and a second base portion 240. The first portion 200 includes a vertically extending wall 230 at the front end of the 2W EV 100. The structure 200 is mounted, through suitable connection means, to the body frame 106.
[0050] The first portion 220 of structure 200 is configured to gather and direct cooling air through it to form a first portion of cooling air for the battery module 24. The second base portion 240 is connected to the first portion 220 and configured to gather and direct cooling air through it to form a second portion of cooling air for the battery module 24. Structure 200 and, in particular, its first and second portions 220 and 240 are further described below.
[0051] The structure 200 here serves a further purpose to heat management and include a portion acting as a floorboard structure for 2W EV 100, for example through the first portion 220 providing a shield for the 2W EV 100 rider and accommodation, in the form of a platform 227 for the rider’s feet. This integration of vehicle functionalities uses space efficiently and reduces bulk for the air cooling system. The structure 200, hereon described as “floorboard structure 200”, is mounted to body frame 106 of motorcycle 100 using suitable connection means. The floorboard structure 200 may be manufactured and supplied as a separate component to, or for, a motorcycle manufacturer.
[0052] The first portion 220 of the floorboard structure 200 is provided, in its vertically extending wall 230, with a plurality of apertures 232 through which cooling air flows (air flow A in Figures 3B and 3C), typically as a ram air flow travelling in opposite direction to 2W EV 100 when ridden in forward gear, into the heat management system. The vertically extending wall 230 is inclined vertically at an acute angle to the horizontal H (as apparent from Figure 6A) and has shape directed to collection of cooling air for direction through the apertures 232. This shape is conveniently a curved shape as apparent from Figures 2A to 2F.
[0053] Advantageously, the vertically extending wall 230 has a concave shaped recess or concavity 234 with apertures 232 recessed or set rearward from front edges 231 of the wall 230. Such concave or curved shape of the recess 234 is selected to accommodate the front wheel well, gather air and minimize, so far as practicable, pressure drop across the apertures 232 that has limited air cooling efficiency in prior heat management systems. The volume of recess 234 is also selected to collect a desired volume of cooling air without increasing dimensions and cost of the first portion 220 and the floorboard structure 200 as a whole.
[0054] The apertures 232 are of shape, area and number, here four but this number may change through optimization to enhance air flow into the heat management system by minimization, so far as practicable, of pressure drop and flow resistance. The shape of apertures 232 is non-circular; rather an irregular though generally angular quadrilateral shape has been selected for cut outs which also reduce the weight of the first portion 220. The objective is to avoid formation of pressure drops that reduce cooling air volumes to a level insufficient to efficiently cool the battery module and maintain the battery module operating temperature within a safe operating range for efficient vehicle operation. This cannot be avoided altogether but the presently described heat management system has, through configuration of structure 200, accessed an additional source of cooling air not available or not efficiently exploited in prior heat management systems for motorcycles.
[0055] The second base portion 240 of the floorboard structure 200 has a curved aerodynamic shape for its side walls 241 and is configured with an open channel 242 and a scoop arrangement 245 on its lower surface, which may oppose a driving surface such as a road surface, to gather and direct the second portion of cooling air (air flow B , as illustrated in Figure 3C and 3E) along an external surface of second base portion 240 to the plenum portion 260 and towards the battery module 24 for cooling as shown in Figures 3A to 3D.
[0056] Such open channel 242, narrowing inwardly to further confine cooling air flow B towards the rear, forms a substantial forward portion of the second base portion 240 and gathers the cooling air which, having been rejected by pressure drop across the first portion 220, is likely to flow under the floorboard structure 200 and the scoop 245 directs the air towards the battery module 24.
[0057] The open channel 242 may have a curved profile to facilitate manufacturing and optimize air flows by reducing causes of turbulence which could adversely affect convective cooling of the battery module 24. Further, profile of the second base portion 240 assist in limiting the reduction is velocity of the air flow B entering the plenum portion 260. Typically, 60% of the velocity of free flowing air flow B under the second base portion 240 is retained, while entering plenum portion 260. This ensures improved cooling performance.
[0058] The channel 242 could be enclosed to form a duct. However, whilst such configuration would harness additional cooling air to the first portion 220, it would do so at the cost of including a pressure drop (similar to that encountered with the first portion 220 and prior heat management systems) and flow resistance that could, more desirably be avoided.
[0059] The entry portion 242a to the channel 242 has an upwardly curved shape acting as an air flow guide to enhance air flow into it. The entry portion 242a also forms part of the transition 224 between the first and second portions 220, 240 of the floorboard structure 200 and is located to collect air which, while gathered by the first portion 220, such as in the concave recess 234 described above cannot pass through the apertures 232 due to flow resistance created by an unavoidable pressure drop across the apertures 232. Such pressure drop and cooling air rejection is intrinsic to scooter type motorcycle operation.
[0060] In prior heat management systems, such rejected cooling air could not be used for the battery module 24 cooling reducing cooling efficiency in contrast to the present heat management system. For example, the channel 242 allows collection of additional air from the front wheel well of motorcycle 100, which otherwise would have escaped from underneath and sides of its body. The floorboard structure 200, as described, helps to capture an additional 40% air flow that has been lost under the floorboard structure in prior heat management system proposals. Such additional flow of air has a significant effect on efficiency of battery cooling.
[0061] Air flow directed to pass through the apertures 232 (air flow A in Figures 3B to 3D) is divided into a plurality of corresponding side channels 222 forming part of the floorboard structure 200. Conveniently, two such side channels 222 are provided. The side channels 220 direct cooling air in the direction of the battery module 24 at sufficient velocity to achieve required convective air cooling.
[0062] One or more deflectors 223 are provided, for example at the rear end of the side channels 222, to guide cooling air towards the battery module 24. The side channels 222 also enable splitting of the first cooling air portion into two air flows and their separation by a volume sufficient to provide a convenient position B for a vehicle battery box (and other vehicle components) as shown in Figure 3C. Air flow A and Air flow B are not allowed to interfere with each other, not being combined until a point closer to the battery module 24. This avoids turbulence and leads to better cooling efficiency.
[0063] To that end, the heat management system 10 for motorcycle 100 further includes a plenum portion 260 (Refer Figure 3D) for combining the first and second portions A and B of cooling air gathered by the floorboard structure and directing the combined cooling air flow C (as shown in Figures 3D) to cool the battery module 24 with the desired fluid dynamic properties to achieve the required convective cooling.
[0064] The plenum portion 260 combines the first and second portions of the cooling air as close to battery module 24 as practicable, avoiding interference between the two portions of cooling air, and minimizing the formation of pressure drops and other flow phenomena which could reduce the available cooling air volume or reduce its efficacy through undesirable fluid dynamic effects. Figures 3A to 3D schematically show cooling air flows throughout the heat management system 10 including floorboard structure 200.
[0065] The plenum portion 260 is separate from, though necessarily in fluid communication with, the floorboard structure 200 and the battery module 24. The plenum portion 260 is formed, at least in part, by the battery module 24 since it is here that the air flow formed by combination of the first and second cooling air flow portions must be directed to flow across the battery module 24 and cool it through convective cooling.
[0066] The battery module 24 is located above and to the rear of the floorboard structure 200. The floorboard structure 220, and particularly the second base portion 240, is therefore configured with the deflectors 223, baffles 290 to direct the cooling air to the plenum portion and onwards and upwards (airflow C of figure 3D) for convective cooling of the battery module 24.
[0067] While the combined cooling air flow C, as described above, cools the battery module 24 and associated electrical components, the air heated in this process rises upwards in the battery module 24 as a result of convection as schematically shown in Figures 3D. The heat management system 10, and particularly the battery module 24 is therefore provided with an exhaust system to enable air heated during the battery module 24 cooling process to be exhausted during both static and dynamic vehicle conditions. Specifically designed vent and grille arrangements are used for this purpose.
[0068] In this case, the 2W EV 100 includes – as shown in Figures 3D and 3E – a storage box 170, mounted under seat 195 and indirect openings or vents for exhausting such heated air are provided by a plurality of cut outs 176 located in the top most portion of under seat cover 175 provided on rear side of the storage box 170 as shown in Figures 3D and 3E. These indirect openings 176 may have covers 177 mounted over them such that sufficient gap is left between the openings 176 and the cover 177 to allow heated air to escape into atmosphere as shown by air flow D in Figure 3D, while preventing any objects falling inside the battery module 24 while the seat 190 is lifted open.
[0069] Further, the rear surface 310 of the bonnet 300 is also provided with a grille arrangement 180 that assists in managing heat build-up by exhausting hot air trapped inside the battery module 24 as shown in air flow E in Figure 3D.
[0070] As illustrated in Figure 4A, in a first exemplary embodiment of present invention, a first fan 910 in the heating management system 10 is accommodated within the second base portion 240, to fasten the circulation of cooling air to the battery module 24. Operation of the fan enhances the cooling efficiency of the heating management system significantly, ensuring hot air around the battery module 24 gets quickly replaced by cool atmospheric air supply. To further enhance the cooling, a second fan 920 is mounted at a distal end of the battery module 24, effectively ensuring faster exit of hot air after battery module 24 cooling. Preferably, the battery is mounted on top side of the battery module 24 to further enhance the air cooling efficiency as illustrated in Figure 4B.
[0071] In an another exemplary embodiment of present invention, an additional fan 930 (Illustrated in figure 5A and 5B) is directly mounted with the battery module 24 at a proximate end of the battery module 24 to intensify and fasten intake of atmospheric air for the battery module 24 cooling as well as it fastens exit of hot air after the battery module 24 is cooled. The additional fan 930 in an exemplary embodiment may replace the fan 910 and the additional fan 920. Hence, any combination of the fan arrangement as detailed above enhances the overall cooling efficiency of the system.
[0072] The heat management system 10 as described herein has a number of advantages avoiding the limitations of ram air cooling systems and enabling the optimization of air cooling of the battery module 24 by harnessing and exploiting cooling air sources not efficiently exploited in prior heat management systems. These advantages are described in detail above.
[0073] Modifications and variations to the heat management system described may be apparent to the skilled reader of this specification. Such modifications and variations are deemed within the scope of the present.
, Claims:1. A heat management system (10) for air cooling of a battery module (24) of a two wheeled vehicle (100) comprising a structure (200);
wherein said structure (200) has a first portion (220) and a second base portion (240);
the first portion (220) includes a substantially vertically extending wall (230) at one end configured to gather and direct cooling air through it to form a first portion (220) of cooling air for the battery module (24); and
the second base portion (240) configured to gather and direct cooling air through it to form a second portion (240) of cooling air for the battery module (24),
characterized in that,
one or more fans or blowers ) induce air cooling flow to the heat management system (10).
wherein the one or more fans or blowers includes a first fan (910) is disposed at least partially below the battery module (24) to induce air.
2. The heat management system (10) according to claim 1, wherein one or more fans or blowers includes an additional second fan (920) disposed above the battery module (24).

3. The heat management system (10) according to claim 1, wherein one or more fans or blowers includes an additional fan (930) directly mounted on the battery module (24) at a proximate end of the battery module (24).

4. The heat management system (10) according to claim 1, wherein the first portion (220) of the structure (200) comprises at least one aperture (232) through which cooling ram air enter into the heat management system (10).

5. The heat management system (10) according to claim 4, wherein the first portion (220) in the form of the substantially vertically extending wall (230) has a shape directed to collection of cooling air for directing through the aperture/s (232).

6. The heat management system (10) according to claim 5, wherein the first portion (220) have the shape in the form of a recess or concavity (234) with aperture/s (232) rearward from edges of a wall of the first portion (220).

7. The heat management system (10) according to claim 4, wherein shape of the aperture/s (232) is preferably non-circular.

8. The heat management system (10) according to claim 1, wherein the first portion (220) of cooling air that pass through the first portion (220) is divided into a plurality of corresponding side channels (222) forming part of a floorboard structure (227).

9. The heat management system (10) according to claim 1, wherein the second base portion (240) is configured with a channel (242) and a scoop arrangement (245) on its lower surface to gather and direct the second portion (240) of cooling air towards the battery module (24).

10. The heat management system (10) according to claim 1, wherein the channel (242) is provided with an entry portion (242a) having an upwardly curved shape to guide an airflow through the second base portion (240).

11. The heat management system (10) according to claim 8, wherein the side channels (222) is provided with a plurality of deflectors (223) at a rear end of the side channels (222) to guide cooling air towards the battery module (24).

12. The heat management system (10) according to claim 10, wherein the entry portion (242a) forms part of a transition between the first portion (220) and the second base portion (240), and is located to collect air in addition to the air passing through the aperture/s (232).

13. The heat management system (10) according to claim 11, wherein the plurality of deflectors (223) and a plurality of baffles (290) at a rear end of the second base portion (240) guide cooling air towards the battery module (24).

14. The heat management system (10) according to any one of the preceding claims, wherein the first portion (220) forms a shield for a rider and accommodation for the rider’s legs and feet.

15. The heat management system (10) according to any one of the preceding claims, wherein the heat management system (10) include a platform (227) for the rider’s feet.

16. The heat management system (10) according to any one of the preceding claims, wherein the heat management system (10) further comprises a plenum portion (260) for combining cooling air from the first portion (220) and cooling air from the second base portion (240) gathered by the floorboard structure (200) and using said combined cooling air flow to cool the battery module (24).

17. The heat management system (10) according to any one of the preceding claims, wherein the battery module (24) is enclosed by a vehicular structure (300) provided with an exhaust system to enable air heated during the battery module (24) cooling process to be exhausted during static and dynamic vehicle conditions.

18. The heat management system (10) according to claim 17, wherein a rear surface of the vehicular structure (300) comprises a grille arrangement (180) that assists in exhausting hot air trapped inside the vehicular structure (300).

19. The heat management system (10) according to any one of the preceding claims, wherein the two wheeled vehicle (100) includes a storage box (170) mounted under a seat (195) and indirect openings by a plurality of cut outs (176) are located in a top most portion of a under seat cover (175), for exhausting heated air.

20. The heat management system (10) according to claim 19, wherein the cut-outs (176) have covers mounted over them such that sufficient gap is left between the cut-outs (176) and the cover to allow heated air to escape into atmosphere.