Multi-Zoned Radiator for Electrified Vehicle Thermal Management

Solution Overview

Problem

Conventional thermal management systems in electrified vehicles require multiple separate heat exchangers, which increase package space, weight, and cost due to their complexity in managing thermal demands across various components.

Innovation Solution

A multi-zoned radiator with distinct fan coverage areas and zones for different temperature ranges, including a low, moderate, and high temperature zone, which allows for separate coolant temperature management for different vehicle components, such as the battery pack, controllers, and engine, using a single radiator with partitioned flow paths and separate manifolds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate heat exchangers are used to manage thermal demands of different components, then thermal management effectiveness is improved, but package space, weight, and cost increase

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidpackage space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines multiple heat exchanger functions into a single integrated radiator structure with multiple zones. The radiator includes a first zone for cooling battery packs and a second zone for cooling other vehicle components, allowing multiple thermal management functions to be performed by one device rather than requiring separate heat exchangers for each component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single radiator is designed to serve multiple functions by incorporating different zones with distinct fan coverage areas. Each zone can independently manage thermal loads for different vehicle components (battery pack, controllers, engine), making the radiator a universal thermal management device that replaces multiple specialized heat exchangers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple separate heat exchangers are used to manage thermal demands of different components, then thermal management effectiveness is improved, but system weight increases

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines multiple heat exchanger functions into a single integrated radiator structure with multiple zones. The radiator includes a first zone for cooling battery packs and a second zone for cooling other vehicle components, allowing multiple thermal management functions to be performed by one device rather than requiring separate heat exchangers for each component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single radiator is designed to serve multiple functions by incorporating different zones with distinct fan coverage areas. Each zone can independently manage thermal loads for different vehicle components (battery pack, controllers, engine), making the radiator a universal thermal management device that replaces multiple specialized heat exchangers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple separate heat exchangers are used to manage thermal demands of different components, then thermal management effectiveness is improved, but system cost increases

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple heat exchanger functions into a single integrated radiator structure with multiple zones. The radiator includes a first zone for cooling battery packs and a second zone for cooling other vehicle components, allowing multiple thermal management functions to be performed by one device rather than requiring separate heat exchangers for each component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single radiator is designed to serve multiple functions by incorporating different zones with distinct fan coverage areas. Each zone can independently manage thermal loads for different vehicle components (battery pack, controllers, engine), making the radiator a universal thermal management device that replaces multiple specialized heat exchangers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution reduces the complexity and cost of thermal management systems by integrating multiple cooling functions into a single radiator, optimizing space and weight while effectively managing thermal loads across various vehicle components.

Implementation Method 1

a radiator fan draws airflow through the radiator

Methodology Applied

Scientific EffectForced Convection: Forced Convection

Implementation Method 2

a radiator equipped with multiple zones... a first zone that includes a first fan coverage area and a second zone that includes a second fan coverage area

Methodology Applied

Scientific EffectHeat Exchanger: Heat Exchanger

Data Source

PatentUS10286774B2Multiple zoned radiator

Publication Date: 2019.05.14 FORD GLOBAL TECH LLC

AI summary

A radiator according to an exemplary aspect of the present disclosure includes, among other things, a first zone that includes a first fan coverage area and a second zone that includes a second fan coverage area that is different from the first fan coverage area.