VEHICLE LOAD FLOOR SUPPORT WITH INTEGRAL AIR DUCT

• US 20090205891A1
• Filed: 02/19/2008
• Published: 08/20/2009
• Est. Priority Date: 02/19/2008
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (Motors Liquidation Co. GUC Trust)
• Inventors: Parrett, Alan V., He, Hua, Stanforth, Kyle W., Roggenkamp, Timothy J.
• Granted Patent: US 8,186,468 B2
• Time in Patent Office: Days
• US Class Current: 180/68.100
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/005 the electric storage means
• CPC Class Codes: B60K 2001/0438 Arrangement under the floor
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2270/142 acoustic
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60R 5/04 arranged at rear of vehicle B60R5/003, B60R5/006 take precedence; external trunks arranged at rear of vehicle B60R9/065
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/952 Housing details

Abstract

A porous, sound absorbing structural foam load floor support is provided that defines an integral duct. The duct is configured as a ventilation air passage from the air outlet of a heat-emitting component, such as an energy storage system in a hybrid vehicle, so that the load floor support serves both to support the load floor as well as to provide a route for heat dissipation. By integrating the duct within the load floor support, a separate duct, which would have to route around other vehicle components located under the load floor, is not required. The structural foam load floor support is configured to absorb noise of a cooling system for the energy storage system. A porous expanded polypropylene foam is especially well-suited for noise attenuation and load floor support.

Claims

1. A vehicle defining a passenger compartment and having an energy storage system for powering the vehicle;

wherein the energy storage system has at least one battery and a cooling system;

wherein the energy storage system is located within the passenger compartment beneath a load floor, comprising;

a load floor support beneath the load floor and adjacent to the energy storage system;

wherein the load floor support forms an integral duct extending from the cooling system to vent the energy storage system; and

wherein the load floor support is configured to reduce cooling system noise.

2. The vehicle of claim 1, wherein the load floor support is a structural porous molded foam that is sound absorbing to reduce battery cooling system noise.

3. The vehicle of claim 1, wherein the load floor support is porous expanded polypropylene foam.

4. The vehicle of claim 1, wherein the vehicle includes vehicle body structure;

wherein the load floor support is included in the vehicle body structure, and further comprising;

a vent in the vehicle body structure operable to allow air flow from the passenger compartment to outside of the vehicle;

wherein the duct is routed from the battery cooling system to the vent to direct cooling air outside of the vehicle.

5. The vehicle of claim 1, wherein the duct has a main passage and at least one side passage in fluid communication with the main passage to act as an acoustic resonator;

and wherein the side passage is configured to reduce cooling system noise.

6. The vehicle of claim 1, wherein the cooling system includes a fan operatively connected to the duct.

7. The vehicle of claim 1, wherein the duct is characterized by a shape to optimize fluid flow and noise attenuation.

8. The vehicle of claim 1, wherein the load floor support forms at least one packaging cavity for a vehicle component.

9. The vehicle of claim 1, wherein the load floor support forming the integral duct is a one-piece component.

10. An apparatus for a vehicle with a heat-emitting component under a load floor comprising:

a structural foam load floor support defining an integral cooling duct in fluid communication with the heat-emitting component for venting heat therefrom.

11. The apparatus of claim 10, wherein the vehicle includes a noise-generating cooling system for the heat-emitting component located adjacent the heat-emitting component under the load floor;

and wherein the duct is configured such that the structural foam load floor support absorbs noise of the cooling system.

12. The apparatus of claim 10, wherein the structural foam load floor support is porous expanded polypropylene foam.

13. A vehicle comprising:

vehicle body structure including a load floor and at least partially defining a passenger compartment above the load floor;

a powertrain including an energy storage system supported below the load floor;

wherein the energy storage system includes an integral cooling fan below the load floor; and

a structural foam load floor support below the load floor adjacent to the cooling fan and forming an integral duct in fluid communication with the cooling fan to vent cooling air used to cool the energy storage system and configured to absorb fan noise.

14. The vehicle of claim 13, wherein the structural foam load floor support is porous expanded polypropylene foam.

15. The vehicle of claim 13, wherein the structural foam load floor support further forms packaging cavities for at least partially securing vehicle components within the vehicle.