Seals the fan to the radiator core so the fan pulls air through the core rather than around it, and holds the fan in position.
A carbon fiber shroud bonded to a PA6-GF fan mount, clamping the Spal fan to the back face of the radiator. Together with the duct on the inlet side it makes the cooling system a sealed diverging-converging path, which is what raises mass flow through the core above what a bare fan would give.
Formed on a 3D printed mold, with the fan mount printed separately in glass-filled nylon and bonded to the CFRP shroud. Geometry follows the radiator core face and the fan diameter.
Packaging inside the sidepod alongside lines, pump and sensors. The radiator's 45 degree forward lean forces the shroud to accommodate that angle. Must be serviceable without removing the undertray.
Sealing performance is evaluated in the ANSYS Fluent porous media model, where any bypass path around the core shows up directly as lost mass flow. From the design reports and one-pagers: CR22 measured the shroud's contribution directly: sealing the fans to the radiator core produced an average 1.5 C drop in cooling system temperature. That is the measurement that justifies the shroud existing at all.
PETG 3D printed mold, vacuum layup, pull, test fit, then bond the printed PA6-GF fan mount. Shroud and duct are sealed to each other with foil tape.
CFRP shroud, PA6-GF30 3D printed fan mount, foil tape for sealing, structural adhesive for the fan mount bond. From the cost report drawings and CAD: From the cost report drawings: Carbon Fiber (Shroud Drawing); Carbon Fiber & Plastic, Nylon (Fan Shroud).
None recorded. This part has no entry in Knowledge_Transfer/Issue Logging/Fault Vault.xlsx, in either Issue Log.xlsx, in CR22/Issue Tracking/Shakedown 7-15-23.xlsx, or in any design review issue list found in CrimsonStorage or Box.
The 3D printed mold replaced a milled foam mold and cut both cost and lead time. Shroud and fan together dropped from 3.75 lb on CR22 to 1.33 lb on CR26I.
CR22 shrouds were 3D printed in PETG at roughly 0.75 lb each, one per radiator. CR26I's CFRP shroud plus fan came to 1.33 lb for the whole installation against CR22's 3.75 lb. From the cost report drawings and CAD: Weighed mass: 600.0 g (1.323 lb) (recorded as: Fan +Shroud). Dimensions called out on the cost report drawings. These are the figures printed on the drawing, not a labelled specification; open the drawing itself for what each one refers to. Shroud Drawing (as drawn): 230.38, 23.04, 76.96, 7.70, 228.60, 22.86, 406.40, 40.64, 258.41, 25.84 Fan Shroud (mm): 245.1, 302.1, 221.3, 171.4, 64.7, 334.7, 235.5, 108.0 Source: Subteam weight books: CR25/Powertrain/Design/Cooling/3 ~ Documentation/Cr25 Cooling Weights.xlsx | Cost report drawings: CR25/Powertrain/Design/Y - Cost Report Drawings/Cooling/Shroud Drawing.pdf; CR26E/Powertrain - EV/Design/Cost Report Drawings/Cooling/Fan Shroud.pdf; CR26i/Powertrain - IC/Design/Y - Cost Report Drawings/Cooling/Shroud Drawing.pdf; CR27i/.Powertrain/Design/Y - Cost Report Drawings/Cooling/Archive/Shroud Drawing.pdf Quantity per car, as costed: 1, 2