Motorcycle Cooler Core Layout for Direct Fan Mounting

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Solution Overview

Problem

Existing motorcycle coolers with bent shapes face challenges in cooling performance due to fan placement limitations, increased air resistance, and complex component mounting, leading to reduced efficiency and increased production costs.

Innovation Solution

A cooler core design featuring a planar middle region with bends on opposite sides allows for improved air flow, centralized and direct fan mounting, and simplified bracket attachment, combining the benefits of both planar and bent cooler cores for enhanced cooling performance and space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a bent cooler core is used to enlarge the area, then the cooling surface area is increased, but the fan cannot be directly mounted and cooling performance is reduced

Engineering Contradiction:

Improvecooler core areaVSAvoidcooling performance

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The cooler core is segmented into a planar middle region and bent side regions. The planar middle region provides a mounting surface for the fan, while the bent side regions increase the overall cooling surface area. This segmentation allows both requirements to be satisfied simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cooler core have different geometric properties. The middle region is planar to accommodate the fan directly, while the side regions are bent to increase surface area. This local differentiation of geometry optimizes both fan mounting and cooling efficiency.

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If a bent cooler core is used to increase surface area, then the lateral extent is maintained, but additional components can only be mounted after bending

Engineering Contradiction:

Improvecooler core surface areaVSAvoidcomponent mounting process

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The bracket is mounted on the cooler core before the bending process. By performing this mounting action preliminarily, on the planar middle region, the subsequent bending of the side regions does not affect the bracket's position or require additional mounting steps.

Inventive Principle:

Principle #10Preliminary action

3Area of stationary object

If a bent cooler core is used, then the area is enlarged, but air flow is deflected and resistance is increased

Engineering Contradiction:

Improvecooler core areaVSAvoidair resistance

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The cooler core is divided into a planar middle region and bent side regions. The planar middle region allows air to flow straight through without deflection, reducing resistance, while the bent side regions still provide increased surface area for heat exchange.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The geometry is optimized locally: the middle region maintains a planar configuration favorable for air flow, while the side regions are bent to maximize surface area. This local differentiation minimizes air resistance while maintaining large cooling area.

Inventive Principle:

Principle #3Local quality

4Area of stationary object

If a bent cooler core is used, then the area is increased, but the design and production costs increase

Engineering Contradiction:

Improvecooler core areaVSAvoidproduction complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The cooler core is segmented into planar and bent regions, allowing standardized production of the planar middle section with bracket pre-mounted, followed by bending of the side regions. This reduces overall production complexity compared to fully bent designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bracket is pre-mounted on the planar middle region before bending, eliminating the need for complex post-bending assembly operations and reducing production complexity and costs.

Inventive Principle:

Principle #10Preliminary action

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 design enhances cooling performance by facilitating larger fan installation and straight air flow, reduces production costs through simultaneous bracket brazing, and optimizes space usage on motorcycles.

Implementation Method 1

the cooler core has cooling fins, wherein the cooling fins are thermally connected to the at least one cooling pipe

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an efficient exchange of heat between the coolant situated in the at least one cooler pipe and the ambient air can take place

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

A fan, which is activated when required, is therefore often provided on the cooler core. Typically, the fan is arranged between the cooler core and the engine and draws air through the cooler core

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentUS20230399069A1Cooler and method for producing a cooler

Publication Date: 2023.12.14 KTM AG

AI summary

A cooler is provided for cooling liquid, in particular of an engine of a motorcycle. The cooler has a plate-like cooler core for exchanging heat between a coolant and ambient air, and the cooler core has a planar middle region. The cooler core has a bend at each of at least two preferably opposite sides of the planar middle region.