ENERGY SOURCE ENCLOSURE SYSTEMS AND METHODS WITH THROUGH-AIR THERMAL MANAGEMENT

• US 20170290204A1
• Filed: 03/31/2017
• Published: 10/05/2017
• Est. Priority Date: 04/04/2016
• Status: Active Grant

• Current Assignee: The Raymond Corporation (Toyota Motor Corporation)
• Original Assignee: The Raymond Corporation (Toyota Motor Corporation)
• Inventors: CRAGNOTTI, JOSEPH E., STOERMER, GREG, HILLIGOSS, LAWRENCE O.
• Granted Patent: US 10,828,974 B2
• Time in Patent Office: Days
• 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 2001/0405 characterised by their position
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2200/42 Fork lift trucks
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60W 2300/121 Fork lift trucks, Clarks
• CPC Class Codes: B66F 9/07595 Cooling arrangements for device or operator
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/617 for achieving uniformity or desired distribution of temperature
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/6556 Solid parts with flow channel passages or pipes for heat exchange closed pipes H01M10/6552
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• CPC Class Codes: H05K 7/20863 Forced ventilation, e.g. on heat dissipaters coupled to components
• CPC Class Codes: H05K 7/20909 Forced ventilation, e.g. on heat dissipaters coupled to components
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

Provided are systems and methods for enclosing an energy source of a material handling vehicle. The systems and methods include an enclosure having a front wall, a rear wall, and an interior compartment, an inlet channel integrally formed with the front wall and in fluid communication with the interior compartment, the air inlet channel defined by an inlet louver and an inlet flange, an outlet channel integrally formed with the rear wall and in fluid communication with the interior compartment, the air outlet channel defined by an outlet louver and an outlet flange, one or more energy source cells positioned within the interior compartment; and a cooling fan in fluid communication with the inlet channel and the interior compartment. The cooling fan operates to draw air through the inlet channel to the interior compartment such that air within the interior compartment is expelled out of the outlet channel.

Claims

1. A system for enclosing an energy source, the system comprising:

an enclosure having a front wall, a rear wall, a top wall, a bottom wall, side walls and forming an interior compartment;

an inlet channel integrally formed with the front wall and in fluid communication with the interior compartment, the inlet channel defined by an inlet louver and an inlet flange, the inlet flange defined by two or more inlet segments;

an outlet channel integrally formed with the rear wall and in fluid communication with the interior compartment, the outlet channel defined by an outlet louver and an outlet flange, the outlet flange defined by two or more outlet segments;

one or more energy source cells positioned within the interior compartment;

a cooling fan in fluid communication with the inlet channel and the interior compartment; and

wherein the cooling fan operates to draw air through the inlet channel to the interior compartment such that air within the interior compartment is expelled out of the outlet channel.

2. The system of claim 1, further comprising a charger positioned within the enclosure and being electrically coupled with the one or more energy source cells.

3. The system of claim 2, further comprising a battery management system positioned within the enclosure and electrically coupled with the one or more energy source cells.

4. The system of claim 3, wherein the one or more energy source cells are positioned below the battery management system and the charger within the enclosure.

5. The system of claim 2, further comprising an electrical cord coupled with the charger.

6. The system of claim 5, further comprising a recessed compartment formed within a top wall of the enclosure, wherein the electrical cord is retractable into the compartment.

7. The system of claim 6, further comprising a wall aperture formed within a side wall of the enclosure that allows water that pools within the compartment to flow out of the compartment.

8. The system of claim 1, further comprising one or more drainage holes formed within the bottom wall of the enclosure.

9. The system of claim 1, wherein the one or more energy source cells includes a first energy source cell and a second energy source cell.

10. The system of claim 9, wherein the first energy source cell is a lithium ion battery cell and the second energy source cell is a lithium ion battery cell.

11. A system for enclosing an energy source for a material handling vehicle, the system comprising:

an enclosure having a first wall, a second wall different than the first wall, and an interior compartment;

an inlet channel integrally formed with the first wall and in fluid communication with the interior compartment, the inlet channel defined by an inlet louver and an inlet flange, the inlet flange defined by two or more inlet segments;

an outlet channel integrally formed with the second wall and in fluid communication with the interior compartment, the outlet channel is defined by an outlet louver and an outlet flange, the outlet flange defined by two or more outlet segments;

one or more energy source cells positioned within the interior compartment;

a charger positioned within the enclosure being electrically coupled with the one or more energy source cells;

a battery management system positioned within the enclosure being electrically coupled with the one or more energy source cells; and

a cooling fan in fluid communication with the inlet channel and the interior compartment;

wherein the cooling fan operates to draw air through the inlet channel to the interior compartment such that air within the interior compartment is expelled out of the outlet channel.

12. The system of claim 11, wherein the one or more energy source cells comprise lithium ion cells.

13. The system of claim 11, further comprising one or more drainage holes within a bottom wall of the enclosure.

14. The system of claim 11, wherein the enclosure satisfies at least an IP3X Ingress Protection rating.

15. The system of claim 11, wherein the cooling fan is secured to at least one of the two or more inlet segments to allow air to pass through the at least one of the two or more inlet segments.

16. The system of claim 11, wherein the cooling fan is positioned in an upper corner of the enclosure and the one or more energy source cells are positioned in one or more lower corners of the enclosure.

17. A method of cooling an energy source comprising:

drawing air through an air inlet channel of an enclosure defined by at least a first wall and a second wall via a cooling fan;

propelling the air, via the cooling fan, into an interior compartment of the enclosure such that the air flows past at least one of an energy source cell, a charger, and a battery management system; and

expelling the air out of an outlet channel that is integrally formed with the second wall and in fluid communication with the interior compartment,

wherein the air inlet channel is defined by an inlet louver and an inlet flange defined by two or more inlet segments, and

wherein the air outlet channel is defined by an outlet louver and an outlet flange defined by two or more outlet segments.

18. The method of claim 17, further comprising:

draining moisture out of the interior compartment through one or more drainage holes positioned within a bottom wall of the enclosure.

19. The method of claim 17, further comprising:

retracting a power cord that extends from a compartment within a recessed compartment formed within a top wall of the enclosure.

20. The method of claim 19, further comprising:

draining water out of the compartment through a wall aperture formed along a side wall of the enclosure.