Air-Cooled Resistor Layout for Uniform Cooling Airflow
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Solution Overview
Problem
Air-cooled resistor arrangements in electric vehicles face challenges in efficiently dissipating electric power during regenerative braking, particularly when the battery's State of Charge is above a certain threshold, leading to overheating and noise issues due to separated air flow regions.
Innovation Solution
An air-cooled resistor arrangement with elongated resistor elements arranged equidistantly in columns and wave-shaped rows within a housing, promoting uniform air flow and reducing separated air flow regions, thereby enhancing heat transfer and operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resistor elements are arranged in conventional configurations, then the structure is simple, but separated air flow regions occur causing pulsations, noise, and reduced heat transfer efficiency
Solution Approach 1:
The resistor elements are segmented into multiple columns (first column, second column, third column) with specific spacing arrangements. This segmentation creates distinct air flow paths between columns, preventing large separated flow regions while maintaining manufacturing simplicity through modular element placement
Solution Approach 2:
The patent employs asymmetric spacing between resistor element columns, with different distances between adjacent columns. This asymmetric arrangement disrupts symmetric flow separation patterns that cause pulsations, creating more uniform air flow distribution across the resistor assembly without significantly complicating the structure
2Area of stationary object
If resistor elements are placed closer together to increase power density, then the device size is reduced, but air flow separation increases causing pulsations and noise
Solution Approach 1:
The patent transitions from a single-row or simple grid arrangement to a multi-column three-dimensional configuration. By distributing resistor elements across multiple columns with vertical and horizontal spacing, the design utilizes additional spatial dimensions to maintain compact overall size while preventing air flow separation through increased flow path complexity
3Ease of manufacture
If uniform spacing is applied to all resistor elements, then manufacturing is simplified, but air flow distribution may not be optimal for heat transfer
Solution Approach 1:
The patent applies different spacing characteristics to different regions of the resistor assembly. Specifically, the horizontal spacing between columns and vertical spacing within columns are optimized independently, allowing local adjustment of air flow characteristics to enhance heat transfer in critical regions while maintaining overall manufacturing simplicity through consistent spacing patterns
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the risk of overheating, noise, and extends the operational lifetime of the resistor elements by ensuring efficient cooling and uniform air distribution, effectively dissipating electric power during regenerative braking.
Implementation Method 1
increase the heat transfer between the elongated resistor elements and the air flowing between the air inlet and the air outlet
Data Source
AI summary
An air cooled resistor arrangement, comprising a resistor housing comprising an air inlet, an air outlet, a first side wall extending from the air inlet to the air outlet, and a second side wall extending from the air inlet to the air outlet on an opposite side to the first side wall, a plurality of elongated resistor elements arranged in the resistor housing, each one of the elongated resistor elements extending from the first side wall to the second side wall, wherein the plurality of elongated resistor elements is arranged in columns along a direction between the air inlet and the air outlet, wherein each one of the plurality of elongated resistor elements is arranged equidistantly to all its neighboring elongated resistor elements.