Radiator with Segmented Bearings for Headlamp Thermal Management

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Solution Overview

Problem

Existing cooling systems for motor vehicle headlights, particularly radiators, often fail to optimally dissipate heat due to suboptimal convection arrangements, leading to increased temperatures and potential electronic failures, and oversized solutions increase material costs and vehicle size.

Innovation Solution

A radiator with optimized convection capacity featuring lower and upper openings on its bearings, lateral and underlying fins, and beveled notches to enhance heat dissipation and airflow, allowing for efficient cooling of multiple electronic components without disrupting air flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional cooling systems are used, then cooling function is provided, but heat dissipation is insufficient leading to increased temperatures

Engineering Contradiction:

Improvetemperature of electronic componentsVSAvoidrisk of electronic failures

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The radiator is divided into multiple bearings (first bearing, second bearing, third bearing) with distinct functions: heat reception, heat dissipation, and air intake. This segmentation allows optimized heat transfer pathways and prevents heat accumulation in specific zones, effectively lowering component temperatures while maintaining system reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The radiator acts as an intermediary thermal management system between the electronic components and the ambient environment. It receives heat from components, transfers it through its structure via conduction and convection, and dissipates it to the environment, thereby protecting components from overheating and failure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If oversized radiator is used to improve cooling, then cooling capacity increases, but material costs and vehicle size increase

Engineering Contradiction:

Improvecooling efficiencyVSAvoidweight and size of lighting module

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

Different regions of the radiator are designed with specific local functions: the first bearing receives heat from components, the second bearing dissipates heat to ambient air, and the third bearing introduces cooling air. This localized functional distribution optimizes cooling efficiency in each zone, allowing effective heat dissipation with a compact overall structure that minimizes material usage and weight

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The radiator utilizes three-dimensional spatial arrangement of bearings and channels to maximize heat dissipation surface area within a compact volume. By stacking bearings vertically and creating multi-level heat dissipation paths, the design achieves high cooling capacity without increasing the horizontal footprint or overall size of the lighting module

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If multiple electronic cards are fixed on radiator, then cooling function is extended, but heat from one card is confined by other cards leading to temperature rise

Engineering Contradiction:

Improvecooling coverage for multiple componentsVSAvoidtemperature of electronic cards

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The radiator is segmented into multiple bearings that can independently support different electronic cards. Each bearing provides a dedicated heat reception and dissipation zone, allowing heat from each card to be managed separately. This prevents heat confinement between cards and enables effective cooling of multiple components simultaneously

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The radiator structure itself provides the mounting support for electronic cards through its bearings, eliminating the need for separate mounting structures. The cards are directly fixed to the radiator, which immediately provides thermal management, allowing the cooling system to serve multiple components while maintaining efficient heat dissipation pathways

Inventive Principle:

Principle #25Self-service

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 solution ensures efficient and rapid cooling of electronic components, reduces material usage, and minimizes the risk of electronic failures while maintaining a compact design, thus improving safety and reducing costs.

Implementation Method 1

The radiator (1) comprises at least two electronic components supported and fixed, respectively, on a lower bearing (1a) and an upper bearing (1b) of the radiator (1), each having a heat dissipation surface

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

each having a heat dissipation surface

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4025828B1Radiator with optimised cooling capacity for motor vehicle headlamp

Publication Date: 2024.01.17 STELLANTIS AUTO SAS

Figure 1
Figure 2A~2B
Figure 3

AI summary

The invention concerns a radiator (1) with optimised convection capacity for cooling a motor vehicle headlamp comprising at least two electronic components (C1, C2) supported and fastened, respectively, to a lower stage (1a) and an upper stage (1b) of the radiator (1), each having a heat-dissipation surface (11a, 11b), characterised in that the radiator comprises bottom openings (10a) and top openings (10b) passing through the stages (1a, 1b) and opening on each stage at the heat-dissipation surface (11a, 11b) of same, and a headlamp equipped with the radiator.