Series Flow Cooling System for Vehicle Engine Thermal Management
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Solution Overview
Problem
Internal combustion engines (ICE) face challenges in effectively managing thermal loads, particularly in critical hot zones like the exhaust ports, where air cooling is insufficient, and traditional liquid cooling systems may not prioritize heat extraction efficiently.
Innovation Solution
A series flow liquid cooling system with serpentine-shaped precision cooling tubes that circulate a coolant medium, such as a mixture of water and glycol, to thermally contact heat exchange surfaces of the rear exhaust ports before the front, ensuring precise cooling and optimal heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used for the engine, then the system is simple and lightweight, but the cooling effectiveness in critical hot zones like exhaust ports is insufficient
Solution Approach 1:
The patent applies local quality by implementing a dual cooling approach: air cooling for general areas and liquid cooling specifically for critical hot zones (exhaust ports and cylinder heads). The liquid cooling circuit is strategically positioned to contact only the most thermally critical surfaces, providing enhanced cooling effectiveness where needed while maintaining system simplicity elsewhere.
2Temperature
If traditional liquid cooling systems are used, then cooling coverage is improved, but heat extraction from critical hot zones is not prioritized efficiently
Solution Approach 1:
The cooling system is segmented into distinct functional zones: a liquid cooling circuit for critical hot zones (exhaust ports and cylinder heads) and air cooling for other areas. The liquid cooling circuit is further divided into multiple passages with different flow rates, allowing prioritized heat extraction from the most critical thermal areas.
Solution Approach 2:
The liquid cooling circuit is positioned to contact the exhaust ports and cylinder heads first in the thermal management sequence, extracting heat from these critical hot zones before the cooling medium proceeds to other less critical areas. This preliminary action ensures that the most thermally sensitive components receive priority cooling.
3Manufacturing precision
If series flow configuration is used with serpentine tubes, then precision cooling of critical hot zones is achieved, but the manufacturing complexity increases
Solution Approach 1:
The cooling tubes are configured in serpentine (sinuous) shapes that follow the contours of the exhaust ports and cylinder heads. This curved configuration allows the cooling medium to maintain intimate thermal contact with complex thermal surfaces, achieving precision cooling while accommodating the three-dimensional geometry of the engine components.
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 configuration enhances thermal management by prioritizing heat extraction from the rear cylinder head, which experiences higher temperatures, thereby improving engine performance and NOx resistance.
Implementation Method 1
liquid cooling relies on flow of a cooling medium/coolant liquid (e.g., refrigerants, oil, etc.) within the engine to absorb heat
Implementation Method 2
use a heat exchanger (e.g., a radiator) to transfer the absorbed heat in the coolant liquid to the ambient environment
Implementation Method 3
the cooling tubes including a rear cylinder precision cooling tube having a serpentine shape that extends through a gap between a pair of rear exhaust ports to thermally contact one or more heat exchange surfaces
Data Source
AI summary
An example liquid cooling system for an internal combustion engine (ICE) of a vehicle, a vehicle having such a liquid cooling system, a cooling circuit for such a liquid cooling system, a method of cooling a vehicle engine. The liquid cooling system having a cooling circuit with a series flow structural configuration that provides precise cooling to the critical hot zones of the cylinder heads.