Evaporator
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Solution Overview
Problem
Air conditioning systems in vehicles face challenges in reducing noise generated by evaporator vibrations without increasing weight or cost, as existing vibration suppression methods using dense materials like unvulcanized butyl rubber are costly and heavy.
Innovation Solution
An evaporator design featuring a two-layer packing system with an inner elastic layer and an outer elastic layer, where the outer layer is softer and has a smaller reaction force upon compression, is used to absorb and minimize vibrations, reducing noise transfer to the vehicle compartment without using heavy or expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a vibration suppression layer made of unvulcanized butyl rubber with large relative density is attached to the evaporator, then vibration and noise are suppressed, but the evaporator becomes heavier and more costly
Solution Approach 1:
The packing is divided into two distinct layers: an inner elastic layer and an outer elastic layer. Each layer serves a specific function - the inner layer provides structural support and close fitting to the evaporator body, while the outer layer provides vibration suppression and noise reduction. This segmentation allows the system to achieve vibration suppression without requiring a single heavy layer of dense material throughout.
Solution Approach 2:
Different regions of the packing have different properties - the inner layer has higher elasticity and density for structural support, while the outer layer has lower elasticity and density for vibration absorption. This local differentiation of material properties allows each layer to perform its specific function optimally while keeping overall weight low.
2Object-affected harmful factors
If a vibration suppression layer made of unvulcanized butyl rubber is attached to the evaporator, then vibration and noise are suppressed, but the evaporator becomes more costly
Solution Approach 1:
The patent replaces expensive unvulcanized butyl rubber with ordinary elastic materials that are cheaper and more readily available. The elastic layers provide sufficient vibration suppression functionality without requiring the use of costly specialized materials, thereby reducing manufacturing costs while maintaining effectiveness.
Solution Approach 2:
The packing uses a composite structure of two different elastic materials with different properties rather than a single expensive material. This composite approach allows optimization of both cost and performance by selecting materials that provide the required functionality at lower cost.
3Weight of moving object
If the evaporator is made light using thin materials, then weight is reduced and fuel economy is improved, but stiffness decreases and vibration occurs
Solution Approach 1:
The elastic packing layers act as intermediaries between the thin evaporator body and the holding portion. These layers provide the necessary support and stiffness to prevent vibration without requiring the evaporator body itself to be thicker or heavier. The packing absorbs and distributes forces, allowing the evaporator to maintain its lightweight construction.
Solution Approach 2:
The elastic packing layers are installed beforehand to provide cushioning and vibration absorption. This pre-installed cushioning system protects the lightweight evaporator from vibration issues before they can occur during operation, eliminating the need for the evaporator structure itself to be over-engineered for strength.
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 effectively limits noise transfer to the driver's seat while reducing the weight and cost of the evaporator by using a packing system that absorbs vibrations without displacing the evaporator, maintaining its position and preventing air leakage.
Implementation Method 1
The packing includes an inner elastic layer closest to the body portion in the packing, and an outer elastic layer closest to the holding portion in the packing
Data Source
AI summary
An evaporator has an outer peripheral side held by a holding portion. The evaporator includes a body portion and a packing located on a part of the body portion that faces to the holding portion. The packing includes an inner elastic layer and an outer elastic layer. The inner elastic layer has a water absorbability smaller than that of the outer elastic layer and is made of a closed cell foam member. The outer elastic layer is made of an open cell foam member. The holding portion includes a first rib preventing an air from flowing along the outer peripheral side of the body portion, and a second rib preventing a displacement of the body portion. A thickness of the outer elastic layer in a condition where the outer elastic layer is not held by the holding portion is larger than a protrusion length of the first rib.