Charge Air Cooler Grille with Deflecting Fins for Wheel Arch Cooling

Solution Overview

Problem

Existing motor vehicle combustion engines face challenges in cooling the charge air due to bulky heat exchangers and discreet yet robust air evacuation requirements, especially in the presence of external aggressions like water, mud, and dust, within increasingly restricted volumes and in wheel arches.

Innovation Solution

A charge air cooler heat exchanger with a cooling air outlet grille in the wheel arch, featuring an upper part with low-deflection fins for minimal airflow slowdown and a lower part with fins oriented to deflect air externally and downwards, protecting the exchanger from water and debris, integrated into the mudguard orifice, with a two-zone design to direct airflow away from the engine compartment and sensitive components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the heat exchanger is made bulky to ensure adequate cooling capacity, then cooling performance is improved, but the available volume in the wheel arch is exceeded

Engineering Contradiction:

Improvecharge air cooling performanceVSAvoidspace required in wheel arch

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The grille is divided into an upper part and a lower part, each with fins oriented in different directions. The upper part has fins oriented to deflect air with minimal slowdown, while the lower part has fins oriented to deflect air externally and downwards, segmenting the airflow management function to optimize both cooling and protection

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different zones of the grille are assigned different fin orientations based on local requirements: the upper part (less exposed to splashes) has horizontal fins for minimal deflection, while the lower part (more exposed to water, mud, gravel) has fins oriented to deflect air externally and downwards for protection

Inventive Principle:

Principle #3Local quality

2Shape

If the air evacuation grille is made discreet to improve aesthetics, then visual appearance is improved, but robustness against external aggressions like water, mud, and dust is reduced

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidexposure to water, mud, and dust

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The fins oriented to deflect air externally and downwards convert the harmful effect of water, mud, and gravel splashes into a beneficial protective mechanism, using the airflow deflection to redirect these external aggressions away from the heat exchanger and engine compartment

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The grille structure with specifically oriented fins provides preliminary protection by deflecting air flows carrying water, mud, and gravel away from sensitive components before these contaminants can reach the heat exchanger or engine compartment

Inventive Principle:

Principle #9Preliminary anti-action

3Object-affected harmful factors

If the fins of the upper part are oriented to deflect air strongly, then protection against external aggressions is improved, but cooling efficiency is reduced due to excessive airflow slowdown

Engineering Contradiction:

Improveprotection against water, mud, and gravelVSAvoidcooling efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The grille is divided into an upper part and a lower part, each with fins oriented in different directions. The upper part has fins oriented to deflect air with minimal slowdown, while the lower part has fins oriented to deflect air externally and downwards, segmenting the airflow management function to optimize both cooling and protection

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different zones of the grille are assigned different fin orientations based on local requirements: the upper part (less exposed to splashes) has horizontal fins for minimal deflection, while the lower part (more exposed to water, mud, gravel) has fins oriented to deflect air externally and downwards for protection

Inventive Principle:

Principle #3Local quality

4Productivity

If the air flow is directed towards the engine compartment for efficient evacuation, then cooling performance is improved, but water and mud can penetrate into the engine compartment

Engineering Contradiction:

Improveairflow evacuation efficiencyVSAvoidwater and mud penetration into engine compartment

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The fins oriented to deflect air externally and downwards convert the harmful effect of water, mud, and gravel splashes into a beneficial protective mechanism, using the airflow deflection to redirect these external aggressions away from the heat exchanger and engine compartment

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The grille structure with specifically oriented fins provides preliminary protection by deflecting air flows carrying water, mud, and gravel away from sensitive components before these contaminants can reach the heat exchanger or engine compartment

Inventive Principle:

Principle #9Preliminary anti-action

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 enhances cooling efficiency while providing robust protection against water, mud, and gravel, preventing accidental engine restarts and maintaining engine compartment dryness, particularly beneficial for vehicles with automatic stop-start systems.

Implementation Method 1

the fins of the lower part are oriented so as to deflect a air flow stronger than the fins of the upper part, and the lower part comprises fins oriented so as to deflect an air flow in the direction of an exterior zone lateral to the vehicle

Methodology Applied

Scientific EffectAir flow deflection:

Implementation Method 2

a charge air cooler heat exchanger and a cooling air outlet grille of the charge air cooler heat exchanger

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentEP3119633B1Grille for a charge air cooler of a motor vehicle

Publication Date: 2019.04.03 PSA AUTOMOBILES SA

Figure 1

AI summary

The invention concerns a grille for discharging cooling air of a heat exchanger of a charge air cooler of a motor vehicle, in which the fins of the lower portion (12) are oriented in such a way as to deflect an air stream more strongly than the fins of the upper portion (11).