Direct-Mount Heat Exchanger Adapter Module for Automotive Cooling
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Solution Overview
Problem
Existing heat exchanger mounting arrangements in automotive systems are cumbersome, contributing to weight, size, and manufacturing cost issues due to the need for complex adapter structures, which also increase the number of potential leakage points and assembly steps.
Innovation Solution
A heat exchanger module with a direct mounting arrangement to the automobile system component housing, featuring a stacked heat exchanger and an adapter module with integrated fluid manifolds and transfer channels, allowing for direct fluid communication and eliminating the need for a thick base plate, thereby reducing weight, size, and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cast or moulded adapter structure is used to mount the heat exchanger to the housing, then the heat exchanger can be incorporated into the vehicle's cooling system with fluid lines and connectors, but the overall height and weight of the heat exchanger component increases
Solution Approach 1:
The adapter structure is merged with the heat exchanger assembly by brazing the adapter plate directly to the heat exchanger plates, eliminating the need for separate cast or moulded adapter structures. This integration reduces the overall weight and height of the component while maintaining adaptability to vehicle cooling systems through the integrated fluid lines and connectors.
2Adaptability or versatility
If a cast or moulded adapter structure is used to mount the heat exchanger to the housing, then the heat exchanger can be incorporated into the vehicle's cooling system with fluid lines and connectors, but the manufacturing costs increase
Solution Approach 1:
The adapter structure is merged with the heat exchanger assembly by brazing the adapter plate directly to the heat exchanger plates, eliminating the need for separate cast or moulded adapter structures. This integration reduces manufacturing costs by simplifying the production process and reducing the number of separate components that need to be manufactured and assembled.
3Strength
If a thick base plate is used to mount the heat exchanger, then the heat exchanger can be mechanically mounted to the housing, but the overall height of the heat exchanger component increases
Solution Approach 1:
The adapter plate is integrated directly with the heat exchanger assembly through brazing, eliminating the need for a thick base plate. This integration provides sufficient mounting strength while significantly reducing the overall height of the heat exchanger component compared to using a separate thick base plate.
4Adaptability or versatility
If a cast or moulded adapter structure with multiple fluid lines and connectors is used, then the heat exchanger can be incorporated into the cooling system, but the number of potential leakage points increases
Solution Approach 1:
The adapter structure is merged with the heat exchanger assembly, reducing the number of separate components and interfaces. This integration reduces the number of potential leakage points while maintaining adaptability to the cooling system through the integrated fluid lines and connectors.
5Adaptability or versatility
If a complex adapter structure with multiple components is used, then the heat exchanger can be mounted to the housing, but the assembly steps and complexity increase
Solution Approach 1:
The adapter structure is merged with the heat exchanger assembly, reducing the number of separate components. This integration simplifies the assembly process by reducing the number of assembly steps and the complexity of the overall structure, while maintaining adaptability to different mounting arrangements.
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 reduces the overall height and weight of the heat exchanger, simplifies assembly, decreases manufacturing costs, and minimizes leakage points by enabling direct mounting and fluid communication, enhancing the adaptability and flexibility of the heat exchanger within the automotive system.
Implementation Method 1
heat exchanger comprising a plurality of stacked heat exchange plates defining alternating first and second fluid flow passages through the heat exchanger
Data Source
AI summary
A heat exchanger module adapted for being mounted directly to the outer surface of the housing of an automobile system component, such as a transmission or engine housing, is provided. The heat exchanger module has a heat exchanger fixedly attached to an adapter module. The adapter module contains one of more fluid transfer channels and includes a portion that extends outwardly beyond the footprint of the heat exchanger. The adapter module is comprised of a first embossed plate that is sealed with a second plate, which may also be embossed. The embossments provide fluid transfer channels and also perform as structural ribs to enhance the rigidity of the adapter module.