Tangential-Flow Cooling Module With Nested Motor for Compact EV Packaging
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Solution Overview
Problem
Existing cooling modules for electric and hybrid motor vehicles are bulky due to the arrangement of the motor outside the housing, which limits space efficiency and ventilation performance.
Innovation Solution
A compact cooling module design with a tangential turbomachine where the motor is located inside the turbine, reducing the module's width by utilizing a vortex airflow and integrating the motor within a hollow cylinder of the turbine blades, and employing a stator fixed to a collector housing for efficient ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the motor is located outside the housing of the cooling module, then the motor can be driven by a tangential turbomachine to generate airflow, but the overall size of the cooling module increases
Solution Approach 1:
The motor is nested inside the turbine housing, with the rotor positioned within the turbine blades' hollow cylinder. This nested arrangement allows the motor to occupy the central space of the turbine rather than requiring external mounting, thereby reducing the overall cooling module volume while preserving ventilation performance.
Solution Approach 2:
The design transitions from a two-dimensional layout (motor outside housing) to a three-dimensional integrated structure (motor inside turbine). By utilizing the vertical space within the turbine housing and positioning components along the rotation axis, the design optimizes space utilization in the width direction of the vehicle.
2Volume of stationary object
If the motor is integrated inside the turbine, then the cooling module volume is reduced, but the motor must be positioned within the hollow cylinder formed by turbine blades
Solution Approach 1:
The motor is nested within the turbine structure, with the rotor positioned inside the hollow cylinder formed by the turbine blades. This nested configuration naturally accommodates the motor within the available space without requiring complex external mounting mechanisms.
Solution Approach 2:
The motor and turbine are merged into a single integrated assembly where the motor housing forms part of the turbine housing structure. The rotor is directly connected to the turbine blades through radial arms, combining the motor drive function with the turbine airflow generation function in a unified structure.
3Productivity
If the rotor is connected to the turbine blades, then the turbine can be driven to generate airflow, but the connection mechanism adds structural complexity
Solution Approach 1:
The rotor and turbine blades are merged through radial arms that extend from the rotor to the turbine blades, creating a direct mechanical connection. This integration eliminates the need for separate transmission mechanisms and simplifies the overall structure while maintaining efficient airflow generation.
Solution Approach 2:
The radial arms serving as connection mechanisms also function as structural support elements and torque transmission components. This multi-functional design reduces the number of separate parts needed and simplifies the connection mechanism while maintaining productivity.
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 reduces the cooling module's volume while maintaining ventilation performance by minimizing the motor's obstruction to airflow, optimizing space utilization, and reducing noise generation.
Implementation Method 1
the flow of the air flow within the turbine is tangential, which creates a vortex in the center of the turbine, that is to say a space in which the flow speed of the air flow is almost zero
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Cooling module (22) comprising a housing (41) configured to accept a tangential-flow turbomachine (30) comprising a turbine (32) with at least one stage of blades (32a, 32b, 32c, 32d and 32e) forming a hollow cylinder (C), the turbomachine (30) also comprising a motor (31) configured to drive the rotation of the turbine (32), the motor (31) comprising a stator (311) and a rotor (312) mounted with the ability to rotate about the stator (311), the cooling module (22) being characterized in that the stator (311) of the motor (31) is secured to the housing (41) in such a way that the blades of the turbine (32) are arranged circumferentially around the rotor (312) of the motor (31), and in that the at least one stage of blades (32a, 32b, 32c, 32d and 32e) of the turbine (32) is mechanically connected to the rotor (312) of the motor (31) so as to be driven in rotation thereby.