Vehicle Heat Exchanger Airflow Flaps for Cooling Backup Paths
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Solution Overview
Problem
Conventional heat exchangers in vehicles face issues with grille shutters failing to open, leading to overheating of components and affecting aerodynamics due to permanently open bypass openings.
Innovation Solution
A system with two flaps, a first flap and a second flap, coupled to different portions of a duct associated with a heat exchanger, allowing independent airflow paths to cool vehicle components, with one flap acting as an active grille shutter and the other as a passive grille shutter, controlled by actuators to manage airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass opening is provided in the grille shutters to prevent overheating, then the reliability of cooling is improved, but the aerodynamic performance deteriorates due to permanently open bypass
Solution Approach 1:
The bypass opening is transformed from a static permanently open structure to a dynamic controllable opening. The second flap can be selectively opened or closed based on cooling requirements, allowing the system to adapt its aerodynamic properties in real-time. When cooling is not needed, the flap remains closed to maintain aerodynamic efficiency; when cooling is needed, the flap opens to provide the bypass airflow path.
Solution Approach 2:
The system uses the existing grille shutter mechanism and airflow paths to provide cooling through the bypass opening, eliminating the need for separate dedicated cooling structures. The second flap integrates with the existing duct system to utilize available airflow for cooling purposes when activated.
2Productivity
If multiple airflow paths are provided through different portions of the duct, then the cooling efficiency is improved, but the device complexity increases
Solution Approach 1:
The duct system is segmented into multiple independent airflow paths, each controlled by a separate flap. The first flap controls the primary airflow path while the second flap controls the bypass airflow path. This segmentation allows independent control of each cooling channel, enabling optimized airflow distribution based on specific cooling requirements without requiring complete system redesign.
3Object-affected harmful factors
If grille shutters are used to control airflow, then the aerodynamic performance is improved, but the reliability of cooling deteriorates when shutters fail to open
Solution Approach 1:
The system incorporates a backup cooling path through the second flap controlled bypass opening. In case the primary grille shutter (first flap) fails to open, the bypass system with the second flap can be activated to provide alternative cooling airflow. This redundancy ensures cooling reliability is maintained even when primary cooling paths fail, cushioning against the harmful effects of shutter failure.
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
Enhances cooling efficiency by allowing airflow from different directions, preventing overheating, and maintaining aerodynamic performance by temporarily opening supplementary grilles only when needed.
Implementation Method 1
Vehicles have heat exchangers to cool components (such as, engines, motors, etc.) of the vehicle based on a flow of fluid (such as air) from a surrounding environment
Data Source
AI summary
A system is provided. The system includes a first flap coupled to a first portion of a duct associated with a heat exchanger of a vehicle. The first flap forms a first airflow path towards the heat exchanger. The system further includes a second flap coupled to a second portion of the duct associated with the heat exchanger of the vehicle. The second flap forms a second airflow path towards the heat exchanger. The first airflow path is different from the second airflow path.