Coupling Device for Heat Exchanger Alignment
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Solution Overview
Problem
The assembly of multiple aluminum heat exchangers in a cooling module is challenging due to manufacturing inconsistencies, misalignment issues, and the rigid nature of aluminum, which complicates the use of conventional mounting hardware, increasing manufacturing costs and complexity.
Innovation Solution
A cooling module design that uses coupling devices with specific brackets and openings to securely connect multiple heat exchangers without conventional mounting hardware, employing snap-fit connections and flexible components to facilitate alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting hardware such as bolts and fasteners is used to couple heat exchangers, then the heat exchangers can be securely assembled, but the assembly process becomes difficult and time-consuming, and manufacturing costs increase
Solution Approach 1:
The coupling device incorporates a flexible coupling member that can deform to accommodate misalignments between heat exchangers. This flexibility allows the components to be assembled quickly without requiring precise alignment, eliminating the need for time-consuming adjustment of conventional fasteners while maintaining secure connection.
Solution Approach 2:
The coupling device acts as an intermediary component between the first and second heat exchangers. It includes a body with openings that receive mounting components from each heat exchanger, and a flexible coupling member that mediates the connection, allowing for misalignment compensation and simplifying the assembly process.
2Adaptability or versatility
If conventional mounting hardware is used to accommodate misalignments, then the heat exchangers can be coupled together, but additional parts must be maintained in the supply chain and assembled, increasing manufacturing complexity and costs
Solution Approach 1:
The coupling device merges multiple functions into a single integrated component. It combines the mounting component reception, alignment accommodation, and secure coupling functions into one device, eliminating the need for separate fasteners, washers, and adjustment mechanisms that would otherwise be required.
Solution Approach 2:
The coupling device is designed to perform multiple functions: receiving mounting components from heat exchangers, accommodating misalignments through its flexible coupling member, and providing secure mechanical connection. This multi-functionality reduces the overall number of parts needed in the assembly.
3Weight of moving object
If aluminum heat exchangers are used to minimize weight and maximize performance, then superior heat transfer and reduced weight are achieved, but manufacturing inconsistencies cause misalignment of mounting components, complicating assembly
Solution Approach 1:
The flexible coupling member is designed beforehand to compensate for potential misalignments that may arise from aluminum heat exchanger manufacturing variations. Its inherent flexibility provides a cushioning effect that absorbs dimensional tolerances and ensures proper assembly even when mounting components are not perfectly aligned.
4Reliability
If aluminum heat exchangers are used to maximize heat transfer performance, then superior thermal efficiency is achieved, but the rigid nature of aluminum makes assembly with conventional mounting hardware difficult
Solution Approach 1:
The flexible coupling member provides the necessary compliance to ease assembly operations. While the aluminum heat exchangers maintain their rigid structure for optimal heat transfer, the flexible coupling member accommodates the rigidity by deforming during assembly, making the process easier and faster without compromising thermal performance.
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 solution simplifies the assembly process, reduces manufacturing costs, and ensures accurate alignment of heat exchangers, enhancing the efficiency and reliability of the cooling module by eliminating the need for conventional fasteners.
Implementation Method 1
The coupling device includes a resilient body of resilient material. The resilient body is resilient in a first direction between a resilient outer surface and a resilient inner surface.
Data Source
AI summary
A cooling module includes a first heat exchanger, a second heat exchanger, and a plurality of coupling devices. The first heat exchanger includes a plurality of first brackets. A pair of the first brackets is disposed on each opposing end of the first heat exchanger. The second heat exchanger includes a plurality second brackets. A pair of the second brackets is disposed on each opposing end of the second heat exchanger. Each of the plurality of the coupling devices includes a first opening and a second opening formed therein. One of the coupling devices is positioned on each of the plurality of the first brackets, wherein each of the first brackets is received in one of the first openings of the one of the coupling devices. The second brackets of the second heat exchanger are inserted into respective ones of the second openings of the coupling devices.