Tangential-Flow Cooling Module for Grille-Free EV Airflow

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Solution Overview

Problem

The absence of a radiator grille in electric vehicles reduces airflow circulation through the cooling module, impairing its performance, especially in electric or hybrid motor vehicles with limited or no cooling openings.

Innovation Solution

A cooling module design featuring a fairing with an internal duct containing heat exchangers, a tangential-flow turbomachine, and fastening elements that secure the heat exchangers to the vehicle chassis, allowing airflow to enter through underbody openings and be directed through the module, with adjustable blocking devices to regulate airflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the radiator grille is removed to improve aerodynamic characteristics, then the aerodynamic performance and range are improved, but the airflow circulation through the cooling module is impeded

Engineering Contradiction:

Improveaerodynamic dragVSAvoidcooling module performance

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The patent inverts the conventional airflow direction by positioning the air inlet at the rear of the vehicle and the air outlet at the front, allowing airflow to enter through the underbody and exit through the radiator grille area. This reversal maintains aerodynamic efficiency while ensuring adequate cooling airflow through the heat exchangers.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent utilizes the vertical dimension by positioning heat exchangers in a stacked arrangement within the cooling module, with at least one heat exchanger located above another. This three-dimensional configuration increases heat exchange surface area while maintaining a compact footprint that preserves aerodynamic performance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of energy

If cooling openings are reduced or eliminated to improve aerodynamics, then the aerodynamic characteristics are improved, but the airflow supply to the cooling module is insufficient

Engineering Contradiction:

Improveaerodynamic dragVSAvoidairflow quantity

Core Design Contradiction:

Loss of energyVSQuantity of substance

Solution Approach 1:

The patent reverses the conventional airflow path by creating a rear inlet and front outlet configuration. This allows the vehicle's forward motion to naturally drive air through the underbody and into the cooling module, eliminating the need for additional front cooling openings while maintaining adequate airflow quantity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The radiator grille area serves dual functions: it acts as the air outlet for the cooling module and maintains its traditional aesthetic and protective roles. This multi-functionality allows the system to achieve adequate cooling airflow without requiring dedicated separate openings.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If the cooling module is positioned without a radiator grille to simplify structure, then the structural complexity is reduced, but the airflow circulation is significantly reduced

Engineering Contradiction:

Improvecooling module structureVSAvoidairflow circulation

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent inverts the airflow direction to enter from the rear and exit at the front, which simplifies the structural integration with the vehicle body by eliminating the need for a separate radiator grille assembly. The airflow circulation is maintained through this reversed path that utilizes the underbody space efficiently.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent merges the cooling module structure with the vehicle's underbody and front bumper areas, integrating the air inlet and outlet paths into existing structural elements. This consolidation reduces overall structural complexity while maintaining adequate airflow circulation through strategic positioning of heat exchangers and air passages.

Inventive Principle:

Principle #5Merging (Combining)

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

Ensures effective airflow circulation and heat exchange even without a radiator grille, enhancing the cooling module's performance and maintaining aerodynamic advantages of electric vehicles.

Implementation Method 1

a tangential-flow turbomachine, itself designed to generate the airflow to be discharged through the air outlet

Methodology Applied

Scientific EffectVortex flow: Vortex Ring

Implementation Method 2

at least one heat exchanger intended to be traversed by the airflow

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS20240253452A1Cooling module for an electric or hybrid motor vehicle, having a tangential-flow turbomachine

Publication Date: 2024.08.01 VALEO SYST THERMIQUES SAS

AI summary

Cooling module for a motor vehicle intended to be traversed by an airflow circulating between an air inlet and an air outlet and including: a fairing forming an internal duct that contains a heat exchanger and including a front face that contains the air inlet, a collector housing designed to receive a turbomachine designed to generate the airflow, fastening elements arranged on both sides of the fairing and enabling the heat exchanger to be fastened to the cooling module, and enabling the module and the heat exchanger to be fastened to a chassis of the vehicle such that the front face of the fairing faces an underbody of the motor vehicle.