Circular Cooling Module Assembly for Vehicle Radiator and Condenser
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Solution Overview
Problem
The existing cooling systems in vehicles face inefficiencies due to the geometry and positioning of radiators and condensers, leading to reduced cooling capacity and increased space requirements, as well as structural weaknesses that result in frequent repairs and replacements, especially in heavy-duty vehicles.
Innovation Solution
A circular cooling module assembly is designed with a radiator and condenser sharing a common plane, surrounded by a durable frame with radial spokes for structural support, allowing maximum cooling from ram air and reducing the occupied space, while the condenser is positioned to receive air that has not previously extracted heat from the radiator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular radiator and condenser are stacked perpendicular to air flow, then packaging is simplified, but cooling efficiency is reduced due to corners not being within fan sweep
Solution Approach 1:
The patent applies curvature by transitioning from rectangular to circular heat exchanger geometry. The circular configuration eliminates corners that are inaccessible to the cooling fan, ensuring uniform cooling across the entire surface. The circular shape maintains manufacturability while significantly improving cooling efficiency and fan coverage.
2Ease of manufacture
If the condenser is positioned in front of the radiator, then packaging is simplified, but radiator cooling capacity is reduced due to heated air
Solution Approach 1:
The circular geometry enables a side-by-side arrangement of the condenser and radiator, both positioned perpendicular to the air flow direction. This configuration allows both components to receive cool ram air simultaneously, eliminating the temperature degradation issue while maintaining compact packaging through the circular footprint.
3Temperature
If the radiator size is increased to compensate for inefficient heat exchange, then cooling capacity is improved, but space requirements increase
Solution Approach 1:
The circular heat exchanger design maximizes the surface area within a compact footprint. The curved geometry provides more efficient heat exchange per unit area, and when combined with the optimal positioning perpendicular to air flow, achieves superior cooling capacity without increasing the overall space occupation.
4Reliability
If a circular heat exchanger is used, then fan coverage is improved, but structural strength is reduced due to impact from hood closing
Solution Approach 1:
The patent employs composite construction by integrating a circular heat exchanger into a robust frame structure. The frame, made from high-strength material, provides the necessary impact resistance from hood closing, while the circular heat exchanger maintains its cooling efficiency. The composite design allows each component to fulfill its primary function without compromising the other.
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, reduces the footprint of the cooling system, and provides structural stability to withstand impact, thereby improving the durability and maintenance efficiency of the cooling system.
Implementation Method 1
Both the radiator and the condenser may rely on liquid-to-air heat exchange to cool the engine block and an interior of the vehicle, respectively
Implementation Method 2
Transfer of heat from the refrigerant and the coolant to air may be enhanced by using a cooling fan to increase air flow across surfaces of the radiator and the condenser
Implementation Method 3
Transfer of heat from the refrigerant and the coolant to air may be enhanced by using a cooling fan to increase air flow across surfaces of the radiator and the condenser
Data Source
AI summary
Methods and systems are provided for a cooling module assembly for a vehicle. In one example, the cooling module assembly includes a first set of fins arranged in a circle, configured to flow a first fluid through a first sinusoidal, continuous inner passage, and a second set of fins, also arranged in a circle and configured to flow a second fluid through a second sinusoidal, continuous inner passage. The second set of fins shares a common plane with the first set of fins and is arranged concentric about the first set of fins.