Rear Differential Cooling System Weight Reduction
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Solution Overview
Problem
Existing motor vehicle powertrain systems face challenges in achieving aerodynamic downforce, reducing drag, and balancing weight distribution, particularly due to the placement of rear axle or differential coolers, which are often front-mounted, leading to weight and aerodynamic inefficiencies and vulnerability to road debris.
Innovation Solution
An aerodynamic body panel system that includes a rear diffuser with air inlets, underbody panels forming air tunnels, and a rear valance with vent openings to direct and increase airflow to a rear-mounted differential heat exchanger, reducing drag and enhancing downforce while protecting the heat exchanger from debris and improving weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rear differential cooler is mounted at the front of the motor vehicle, then the cooler is easily accessible and protected from road debris, but the weight distribution becomes unbalanced and aerodynamic drag increases
Solution Approach 1:
The patent inverts the conventional front-mounted cooler arrangement by placing the rear differential cooler at the rear of the vehicle behind the rear axle. This inversion resolves the contradiction by achieving both goals: the cooler is protected from road debris through strategic positioning in the rear valance area, and weight distribution is improved by locating the heavy cooler close to the rear differential, eliminating the need for long fluid lines and large pumps.
2Weight of moving object
If the rear differential cooler is mounted at the rear of the motor vehicle, then weight distribution improves and aerodynamic drag reduces, but the cooler becomes vulnerable to impact from stones and debris
Solution Approach 1:
The patent applies nesting by placing the rear differential cooler within the rear valance structure, specifically in the area bounded by the rear diffuser, underbody panel, and rear valance. This nested positioning achieves dual benefits: the cooler is protected from road debris by the surrounding structural elements, and weight distribution is optimized by locating the cooler close to the rear differential.
3Ease of operation
If long fluid lines extend from front-mounted coolers to the rear differential, then the cooler can be positioned for accessibility, but the cooling system weight increases and pump size must increase
Solution Approach 1:
The patent extracts the cooler from its conventional front-mounted position and relocates it to the rear of the vehicle. This extraction eliminates the need for long fluid lines extending from the front to the rear, thereby reducing cooling system weight and allowing for a smaller pump while maintaining effective cooling through the new rear-mounted configuration.
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 effectively reduces aerodynamic drag, enhances rear downforce, and improves weight distribution, leading to better motor vehicle handling and reduced risk of heat exchanger damage from road obstructions, while also minimizing the weight and complexity of the cooling system.
Implementation Method 1
the aerodynamic body panel system takes advantage of the momentum of the passing air flow to feed air to a rear differential heat exchanger
Implementation Method 2
The heat exchanger may provide cooling to a rear differential of a motor vehicle
Data Source
AI summary
A method and apparatus are provided to reduce the overall weight of a rear differential cooling system of a motor vehicle. The apparatus includes a body panel system. That body panel system includes (a) a rear diffuser, having a front air inlet, (b) an underbody panel, overlying the rear diffuser as well as (c and d) first and second air tunnels formed between the rear diffuser and the underbody panel, and (e) a rear valance, including first and second vent openings for discharging air received from the first air tunnel. A heat exchanger is provided between the air tunnels and the vent openings. A related method for improving weight distribution and reducing overall weight of a rear differential cooling system is also provided.