Intercooler-Radiator Layout for Higher Engine Cooling Efficiency
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Solution Overview
Problem
Existing engine cooling systems for internal combustion engines suffer from low heat exchange efficiency due to inefficient use of temperature distribution characteristics, leading to larger and heavier cooling modules with high energy consumption and noise, as well as wastage of cooling air.
Innovation Solution
A novel cooling system design where an intercooler is positioned between two water radiators, forming a heat exchange unit with a cooling fan blowing cooling air in a serial and parallel configuration to maximize heat exchange efficiency, reducing the size and weight of the cooling system and minimizing fan power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a series type structure is used where water radiator and intercooler are arranged in series, then the cooling air can sequentially cool both components, but the cooling effect of the water radiator is greatly deteriorated due to the large temperature increase of cooling air after passing through the intercooler
Solution Approach 1:
The cooling system is segmented into two independent parallel paths: one path for the water radiator and another path for the intercooler. This segmentation allows each component to receive fresh cooling air independently, preventing the deterioration of cooling effect while maintaining structural organization.
Solution Approach 2:
The system transitions from a one-dimensional series arrangement to a two-dimensional parallel arrangement with air flow distribution. Cooling air is divided into different streams that can simultaneously serve multiple components, adding a dimensional aspect to the cooling architecture.
2Productivity
If a parallel type structure is used where water radiator and intercooler are arranged in parallel, then both components can receive cooling air simultaneously, but the cooling air has small temperature increase and is wasted without sufficient heat exchange
Solution Approach 1:
Instead of discarding the warming cooling air after a single heat exchange, the system recovers it by routing the air through a second heat exchanger. The cooling air that has warmed after passing through one component continues to absorb heat from another component, maximizing its heat absorption capacity before being exhausted.
Solution Approach 2:
The cooling air continues its useful heat absorption action through multiple components in sequence rather than completing a single heat exchange and being discarded. The warming process is continuous as the air progresses through different heat exchangers, extending the useful action duration.
3Ease of manufacture
If traditional cooling systems are used with separate water radiators and intercoolers, then each component can be independently designed, but the overall cooling module becomes large and heavy with high energy consumption
Solution Approach 1:
The water radiator and intercooler are merged into a single integrated heat exchange unit where both components share common structural elements, cooling air pathways, and mounting mechanisms. This combining reduces the overall size and weight while maintaining the independent design flexibility of each component through modular internal architecture.
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 system achieves higher heat exchange efficiency by fully utilizing temperature differences across the intercooler and water radiators, reducing the size and weight of the cooling unit, lowering energy consumption, and maximizing overall cooling efficiency.
Implementation Method 1
a cooling fan 3 is provided on outer sides of the water radiator a and the intercooler b, and the cooling fan c blows cooling air into the second core body b-3
Implementation Method 2
the water radiator a and the intercooler b are provided in series; the water radiator a is provided with a water inlet pipe a-1, a water inlet chamber a-2, a first core body a-3
Data Source
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AI summary
The invention provides a novel cooling system for an internal combustion engine, which comprises a cooling fan, a first water radiator, an intercooler and a second water radiator, wherein the intercooler is positioned between the first water radiator and the second water radiator; the first water radiator is positioned at one end, close to an air inlet pipe, of an air inlet side of the intercooler, and the second water radiator is positioned at one end, close to an air outlet pipe, of an air outlet side of the intercooler; and the first water radiator, the intercooler and the second water radiator jointly form a heat exchange unit, and the cooling fan is provided on an outer side of the heat exchange unit. According to the invention, the heat exchange is more sufficient, the efficiency is higher, the water resistance is smaller, the cold air demand is less.