Additive Heat Exchanger Assembly for Vehicle Space Constraints
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Solution Overview
Problem
Conventional heat exchangers in motor vehicles face challenges in integration and space utilization due to their rectangular shape, making it difficult to accommodate multiple exchangers in a bundle and adapt to the limited structural space, especially when considering vehicle components like bumpers and engine hood locks.
Innovation Solution
The heat exchanger assembly is manufactured using additive manufacturing, featuring recesses and changes in direction of exchanger tubes to bypass vehicle components, allowing for a non-rectangular shape that adapts to the available space and includes thermally insulating connecting elements to form a bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional rectangular heat exchanger is used, then the manufacturing and assembly process is simple, but the space utilization is poor and integration with vehicle components is difficult
Solution Approach 1:
The heat exchanger is divided into multiple modules (first heat exchanger module, second heat exchanger module, etc.), each with its own end tanks and exchanger tubes. These modules can be independently manufactured and then assembled together, combining the simplicity of standardized manufacturing with the flexibility of configurable arrangements to adapt to different vehicle spaces and component layouts.
Solution Approach 2:
The patent transitions from conventional two-dimensional rectangular heat exchanger layouts to three-dimensional modular configurations. The modules can be arranged in various spatial configurations (side-by-side, stacked, angled) and can incorporate vehicle components within their structures, utilizing vertical and lateral dimensions to maximize space utilization while maintaining manufacturing simplicity through standardized module designs.
2Adaptability or versatility
If multiple heat exchangers are grouped in a bundle, then the space utilization improves, but the structural complexity and difficulty of assembly increase
Solution Approach 1:
Multiple heat exchanger modules are merged into integrated bundles where adjacent modules share common structures (such as shared end tanks or connecting walls). This merging reduces the total number of separate components, simplifies the assembly process by reducing the number of connections required, while still achieving high space utilization through the compact bundled configuration.
Solution Approach 2:
The heat exchanger modules are designed with universal interfaces and standardized dimensions that allow them to be configured in multiple bundle arrangements. The same basic module can be used in different positions and orientations within a bundle, and can accommodate various vehicle components, reducing assembly complexity through interchangeability while maintaining adaptability to different space requirements.
3Adaptability or versatility
If vehicle components are accommodated within the heat exchanger structure, then the space utilization is maximized, but the fluid flow paths become more complex
Solution Approach 1:
The heat exchanger modules incorporate vehicle components (such as bumpers, engine hood locks, or other vehicle parts) locally within specific regions of the module structure, rather than requiring the entire heat exchanger to accommodate all components. The fluid flow paths are designed to bypass these locally integrated components through dedicated channels, maintaining simple flow paths in the majority of the heat exchanger volume while achieving high overall space utilization.
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 design enhances space utilization by accommodating vehicle components without disrupting fluid flow, reduces turbulence, and allows for efficient heat exchange, even in confined spaces.
Implementation Method 1
The exchanger core generally consists of a plurality of spaced-apart exchanger tubes which are largely responsible for the heat exchange between the fluid and the ambient air
Implementation Method 2
The heat exchangers are connected by at least one additively manufactured, thermally insulating connecting element to form a heat exchanger bundle
Data Source
AI summary
A heat exchanger assembly for a motor vehicle includes a heat exchanger formed by additive manufacturing. The heat exchanger includes two end tanks and a plurality of exchanger tubes. The plurality of exchanger tubes extend in a transverse direction relative to a longitudinal direction of the motor vehicle and connects the two end tanks to each other such that fluid is allowed to flow between the two end tanks by the plurality of exchanger tubes. The heat exchanger has a recess formed therein. A first exchanger tube of the plurality of exchanger tubes has at least one change of direction such that the first exchanger tube bypasses the recess at an angle to the transverse direction and runs along a side of the recess.