Vehicle Air Conditioner Evaporator Baffle Design
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Solution Overview
Problem
Conventional vehicle air conditioners face issues with air leaks and condensate overflow due to the inability to effectively block air between the evaporator and the air-conditioning case, leading to temperature increase and potential malfunction of temperature adjusting doors when condensate exceeds the drainable amount.
Innovation Solution
Incorporating a blocking member, specifically a first baffle that protrudes from the air-conditioning case to block air and condensate between the heat exchanger and the discharge part, which includes a drain hole positioned downstream of the cooling heat exchanger to prevent air leaks and condensate overflow by acting as a buffer before discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a groove-shaped drain channel is formed in the bottom surface to discharge condensate, then condensate can be discharged smoothly, but air leaks occur and condensate overflows when excessive condensate is generated
Solution Approach 1:
The drain channel is segmented into multiple sections: a first drain channel section, a second drain channel section, and a third drain channel section. Baffles are strategically positioned to divide the flow path, creating separate zones for air flow and condensate discharge. This segmentation prevents air from mixing with condensate while ensuring smooth condensate discharge, resolving the contradiction between discharge efficiency and leak prevention.
Solution Approach 2:
A blocking member (baffle) is introduced as an intermediary element between the evaporator and the drain channel. This baffle acts as a mediator that blocks air from entering the drain channel while allowing condensate to pass through. The blocking member resolves the contradiction by selectively permitting condensate flow while preventing air leakage, thereby improving both discharge efficiency and reliability.
2Ease of operation
If the air-conditioning case bottom surface is inclined downwardly to facilitate condensate discharge, then condensate flows smoothly, but air introduced through gaps causes temperature increase and potential door malfunction
Solution Approach 1:
The drain channel is divided into multiple sections with baffles positioned at strategic locations. The first drain channel section receives condensate from the evaporator, the second section handles the transition zone with the blocking member, and the third section leads to the drain hole. This segmentation creates distinct functional zones that maintain smooth condensate flow while preventing air from reaching the discharge area, thus resolving the contradiction between ease of discharge and harmful air infiltration.
Solution Approach 2:
The blocking member serves as an intermediary that separates the air flow path from the condensate discharge path. Positioned in the second drain channel section, it blocks air from entering the drain channel while permitting condensate to flow through to the drain hole. This intermediary element eliminates the harmful effect of air leakage while preserving the smooth discharge function provided by the inclined bottom surface.
3Device complexity
If no blocking member is installed between the evaporator and drain hole, then the structure remains simple, but air leaks occur and condensate overflows toward the temperature adjusting door
Solution Approach 1:
The drain channel is segmented into three distinct sections with two baffles positioned at key locations. The first baffle separates the evaporator area from the drain channel, the second baffle separates the second and third sections. This segmentation provides reliable air and condensate flow control while maintaining relatively simple construction using standard manufacturing techniques, thus balancing device complexity with reliability improvement.
Solution Approach 2:
Blocking members (baffles) are introduced as intermediary elements that prevent both air leakage and condensate overflow. These baffles are strategically positioned to block harmful air flow while permitting condensate discharge. The use of simple baffle structures provides reliable protection against air leaks and condensate overflow without significantly increasing device complexity, as they can be easily integrated into the existing air-conditioning case structure.
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 effectively prevents air leaks and condensate overflow, enhancing heat pick-up, preventing temperature increase, and improving the durability of the air conditioner by optimizing the arrangement of baffles to manage condensate discharge and air flow.
Implementation Method 1
a blocking member for blocking at least some of air or condensate is arranged at a predetermined area between the heat exchanger and the discharge part
Implementation Method 2
a first baffle protruding from the bottom surface of the air-conditioning case... to prevent air leaks and condensate overflow by acting as a buffer before discharge
Implementation Method 3
a drain hole, which is disposed at the downstream side of the cooling heat exchanger in an air flow direction to discharge the condensate to the outside
Data Source
AI summary
An air conditioner for a vehicle which can block air introduced through a gap between an evaporator and an air-conditioning case and prevent condensate from overflowing toward a temperature adjusting door when condensate exceeding a drainable amount is generated. The air-conditioning case has an air passageway therein. An evaporator is disposed in the air passageway. A drain hole is disposed at a downstream side of the evaporator in an air flow direction to discharge condensate to the outside. A first baffle protrudes upwardly from a bottom surface of the air-conditioning case for preventing air from leaking between the air-conditioning case and the evaporator.


