Vehicle Cooling Module With Reversible Airflow Heat Exchangers
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Solution Overview
Problem
Current cooling systems for electric and hybrid vehicles face challenges in simultaneously dissipating heat generated during rapid charging and maintaining passenger compartment comfort while minimizing system size and noise pollution, especially during high-temperature conditions.
Innovation Solution
A cooling module with a dual heat exchanger system and a ventilation device that selectively directs air flow between the heat exchangers to optimize thermal performance, using a Coanda effect tube for reduced noise and size, and incorporating a sealed air circulation path to enhance heat transfer and reduce recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the refrigerant circuit is sized to cool the energy storage element during rapid charging, then the energy storage element temperature is controlled, but the passenger compartment cooling performance deteriorates and system size increases
Solution Approach 1:
The cooling system is segmented into two independent circuits: a first cooling circuit for the energy storage element and a second cooling circuit for the passenger compartment. This segmentation allows each circuit to be optimized independently, enabling the energy storage element to be cooled during rapid charging without compromising passenger compartment cooling performance, while avoiding the need for an oversized integrated system.
Solution Approach 2:
The first cooling circuit serving the energy storage element is designed to perform multiple functions: cooling the energy storage element during rapid charging and cooling the electric motor during vehicle operation. This multi-functionality eliminates the need for separate dedicated cooling systems for each component, reducing overall system size while maintaining effective temperature control for both applications.
2Temperature
If intensive use of ventilation device and air conditioning circuit is made to compensate for overheating during fast charging, then cooling performance is improved, but noise pollution increases
Solution Approach 1:
By segmenting the cooling functions into separate circuits, the system eliminates the need for intensive operation of the air conditioning circuit during fast charging. The first cooling circuit independently handles energy storage element cooling, allowing the second circuit to maintain normal, quiet operation for passenger comfort without generating excessive noise.
Solution Approach 2:
The energy storage element cooling is achieved through the dedicated first cooling circuit operating independently during fast charging, without requiring the air conditioning circuit to compensate. This self-service approach to thermal management prevents the need for high-speed fan operation and intensive air conditioning use, thereby avoiding noise pollution.
3Device complexity
If a single cooling circuit is used for both energy storage element and passenger compartment, then system size is reduced, but the ability to simultaneously meet both cooling requirements deteriorates
Solution Approach 1:
The system uses segmentation to create two separate cooling circuits that can operate independently and simultaneously. The first cooling circuit is dedicated to the energy storage element while the second serves the passenger compartment, enabling both to be cooled at the same time without thermal interference, while keeping each circuit compact and efficient.
Solution Approach 2:
The cooling system incorporates dynamic control capabilities where the first cooling circuit can be activated specifically during rapid charging operations to cool the energy storage element, while the second circuit continues to operate for passenger comfort. This dynamic adaptability allows the system to respond to different operational requirements without increasing overall system size.
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 effectively maintains energy storage elements below a threshold temperature during rapid charging and provides optimal passenger compartment cooling, improving thermal performance without increasing system size or noise pollution.
Implementation Method 1
a ventilation device (3) arranged to selectively generate, within the air circulation path (99), an air flow (FA) in a first direction (FA1), from the first exchanger (1) to the second exchanger (2)
Implementation Method 2
an air flow (FA) in a second direction (FA2), from the second exchanger (2) to the first exchanger (1)
Implementation Method 3
a first heat exchanger (1) arranged to be connected to a first cooling circuit (10), in particular dedicated to the cooling of at least one electric motor (11) and at least one power electronics element (13)
Implementation Method 4
a second heat exchanger (2) to be connected to a second cooling circuit (20), in particular dedicated to the cooling of at least one energy storage component (12) of the vehicle
Implementation Method 5
using a Coanda effect tube for reduced noise and size
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a cooling module (100) for a motor vehicle (9) comprising: – a first heat exchanger (1) designed to be connected to a first cooling circuit (10), – a second heat exchanger (2) designed to be connected to a second cooling circuit (20), – an air-circulation path (99) in which the first (1) and second (2) heat exchangers are at least partially positioned, and – a ventilation device (3) designed to selectively generate, within the air-circulation path (99), an airflow (FA): ◦ in a first direction (FA1), from the first exchanger towards the second exchanger, and ◦ in a second direction (FA2), from the second exchanger towards the first exchanger.