Frameless Cooling Module L-Shaped Bracket Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and cost of traditional cooling modules for internal combustion engines increase with size and power, leading to intricate and expensive structural frames that complicate assembly and maintenance, especially when servicing or replacing heat exchangers.
Innovation Solution
A frameless cooling module design utilizing L-shaped stiffener brackets and shroud panels that extend from the front to the back and top to bottom, providing structural support while allowing for easier assembly and maintenance, with heat exchangers indirectly secured to these brackets for improved accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional frame structure with multiple U-channels and gussets is used to provide structural support, then structural rigidity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate structural elements (U-channels and gussets) into a single integrated C-channel structure. The C-channel's continuous design with integrated flanges eliminates the need for separate gusset plates to reinforce joints, thereby reducing part count while maintaining structural rigidity through the channel's inherent geometry and wall thickness.
Solution Approach 2:
The C-channel structure serves multiple functions simultaneously: it provides structural support, acts as a mounting frame for heat exchangers, and offers structural rigidity through its geometry. This multi-functional design replaces the traditional frame that required separate components for each function, simplifying the overall structure.
2Strength
If a traditional frame structure with multiple fasteners and gussets is used, then structural rigidity is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The C-channel structure integrates the functions of multiple U-channels and gussets into a single continuous component. This integration eliminates numerous fastener locations that would be required to assemble separate U-channels and gussets, significantly reducing assembly time while maintaining the structural rigidity through the channel's continuous geometry.
3Strength
If a traditional frame structure is assembled before heat exchanger installation, then structural support is provided, but ease of servicing and replacement of heat exchangers deteriorates
Solution Approach 1:
The C-channel structure is designed with open ends and integrated mounting features that allow heat exchangers to be independently installed and removed. The continuous C-channel provides structural support while its geometry allows heat exchangers to be slid in or out without disassembling the frame, enabling easy servicing and replacement.
4Ease of repair
If the frame structure is disassembled for heat exchanger replacement, then ease of servicing is improved, but assembly complexity and time increase
Solution Approach 1:
The integrated C-channel structure combines structural support and heat exchanger mounting functions into a single component. This design allows heat exchangers to be serviced without disassembling the frame, eliminating the complexity of reassembling multiple frame components while maintaining easy access for maintenance.
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A frameless cooling module includes a first and a second shroud panel arranged at opposing sides of the module and extending from the front of the module to the back of the module. At least one L-shaped stiffener bracket extends between the panels at an intermediate location along both the height direction and the depth direction of the module. One or more heat exchangers is arranged within the cooling module between the L-shaped stiffener bracket and the front of the module, and is at least partially secured within the cooling module by being mounted to the L-shaped stiffener bracket.