Tangential-Flow EV Cooling Module for Single-Bay Heat Exchange
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Solution Overview
Problem
Conventional cooling modules for electric motor vehicles are inefficient due to the reduced number of cooling bays, which affects the cooling of heat exchangers and compromises aerodynamic performance.
Innovation Solution
A cooling module with heat exchangers sized for cooling by a single lower cooling bay, utilizing a tangential turbomachine to create a more efficient air flow through the heat exchangers, and incorporating a structural and acoustic insulation design using different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling modules with multiple cooling bays are used in electric vehicles, then heat exchangers can be adequately cooled, but aerodynamic performance deteriorates and vehicle range decreases
Solution Approach 1:
The heat exchanger is divided into multiple independent modules (first heat exchanger module, second heat exchanger module, third heat exchanger module) arranged in series within a single cooling bay. This segmentation allows each module to be efficiently cooled by the limited air flow from one cooling bay while maintaining compact overall dimensions that preserve aerodynamic performance.
Solution Approach 2:
The cooling solution transitions from a horizontal arrangement (multiple cooling bays side-by-side) to a vertical arrangement (multiple heat exchanger modules stacked in series within a single cooling bay). This dimensional change enables adequate cooling of all heat exchanger surfaces using air flow from a single lower cooling bay, eliminating the need for multiple cooling bays and thus preserving aerodynamic characteristics.
2Productivity
If a single lower cooling bay is used in electric vehicles, then aerodynamic characteristics improve, but heat exchanger cooling efficiency deteriorates
Solution Approach 1:
The heat exchanger system is segmented into multiple small modules arranged in series, where each module receives a portion of the air flow from the single cooling bay. This segmentation ensures that no single heat exchanger module is oversized for the limited air flow available, maintaining effective cooling efficiency despite using only one cooling bay.
Solution Approach 2:
Each heat exchanger module is designed with dimensions optimized for its specific position in the series arrangement and its local air flow conditions. The modules are sized and configured to maximize heat exchange efficiency given the constrained air flow from the single cooling bay, with each module adapting to its local thermal and fluid dynamic environment.
3Temperature
If heat exchangers are sized for single cooling bay cooling, then cooling efficiency improves, but device complexity increases
Solution Approach 1:
Multiple heat exchanger modules are merged into a single integrated assembly housed within one cooling bay, sharing common structural support, air flow path, and control systems. This merging approach achieves the cooling efficiency of multiple independently sized exchangers while reducing overall system complexity compared to managing separate cooling systems for each bay.
Solution Approach 2:
The single cooling bay is designed to serve multiple functions by cooling all heat exchanger modules through a unified air flow path. The modular heat exchanger design allows the same basic module configuration to be replicated and arranged in series, creating a universal solution that achieves efficient cooling without requiring complex custom designs for each cooling zone.
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
The solution provides improved cooling efficiency for electric motor vehicles, enhances aerodynamics, and maintains a compact size, thereby extending the vehicle's range and top speed.
Implementation Method 1
a tangential turbomachine (28) creating a tangential air flow through said heat exchangers
Implementation Method 2
a ventilation device adapted to generate an air flow in contact with the at least one heat exchanger
Implementation Method 3
at least one heat exchanger and a ventilation device adapted to generate an air flow in contact with the at least one heat exchanger
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a cooling module (22) for an electric motor vehicle, comprising: - at least one heat exchanger; - at least a first tangential-flow turbomachine (28-1) capable of creating an air flow that comes into contact with the at least one heat exchanger; and - a shroud (24) for accommodating the at least one heat exchanger and/or at least a first tangential-flow turbomachine, wherein the shroud (24) comprises a structural part (38) and an acoustic insulation part (40) supported by the structural part (38).