Fuel Cell Vehicle Radiator Layout to Reduce Hot Air Recirculation
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Solution Overview
Problem
Fuel cell electric vehicles (FCEVs) face challenges in efficiently placing and orienting radiators due to increased heat rejection and space constraints, leading to suboptimal air flow and heat rejection capabilities compared to internal combustion engine vehicles.
Innovation Solution
The strategic placement and orientation of radiators and baffles above the chassis, with adjustable angles to reduce hot air recirculation and air restriction, optimizing air flow and heat ejection by utilizing gaps between or behind fuel tanks, and incorporating angled baffle configurations to enhance airflow and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If radiator size is increased to reject more heat from fuel cells, then heat rejection capability is improved, but available space on the vehicle is reduced
Solution Approach 1:
The radiator is repositioned from a horizontal placement in the engine bay to a vertical orientation above the chassis, utilizing the vertical dimension of the vehicle. This dimensional change allows the radiator to occupy space that would otherwise be unused, accommodating larger radiator surface area without encroaching on horizontal vehicle space for cargo or passengers.
Solution Approach 2:
The thermal management system is segmented into multiple radiators distributed at different locations on the vehicle (above chassis, in engine bay, side placements) rather than relying on a single large radiator. This segmentation allows heat rejection functionality to be distributed across multiple smaller units that collectively provide sufficient cooling surface area.
2Area of stationary object
If radiator is placed in areas with limited space constraints, then space utilization is improved, but air flow efficiency is reduced
Solution Approach 1:
Baffles are introduced as intermediary structures between the radiator and surrounding components. These baffles act as mediators that actively manage and direct air flow toward the radiator, ensuring that even in constrained spaces above the chassis, sufficient high-velocity air flow can be channeled through the radiator cores for effective heat rejection.
Solution Approach 2:
Air flow paths are pre-configured using baffles and ducting before air reaches the radiator. The baffles are positioned to pre-direct and accelerate air flow toward the radiator inlet, ensuring optimal air velocity and distribution is achieved at the radiator before heat exchange occurs, compensating for the constrained placement location.
3Temperature
If air flow rate is increased to improve heat rejection, then heat rejection capability is improved, but fan power consumption increases exponentially
Solution Approach 1:
The vertical orientation of the radiator above the chassis creates a more favorable pressure differential for natural convection and ram air flow compared to horizontal placements. This dimensional reconfiguration reduces the additional power required by fans to achieve the same heat rejection, as the vertical geometry better utilizes vehicle motion and thermal buoyancy to drive air flow through the radiator.
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 improves air flow and heat rejection capabilities, allowing for more efficient fuel cell performance and reduced power consumption by fans, while maximizing available space on the vehicle.
Implementation Method 1
radiators... to release excess engine heat to the ambient air
Implementation Method 2
radiators... to release excess engine heat to the ambient air
Implementation Method 3
one or more baffles extending between the one or more radiators and the tank storage region... to reduce hot air recirculation and air restriction
Data Source
AI summary
The present disclosure relates to improved placement, positioning, and/or orientation of radiators and baffles on a vehicle to improve and/or optimize air flow, radiator, and fuel cell performance.