Heat Exchanger Header Buffering to Prevent Damping Material Peeling
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Solution Overview
Problem
In vehicle air conditioners, the damping material used in heat exchangers to suppress noise can peel off due to decreased adhesive force caused by condensate water or aging, leading to vibration and noise issues.
Innovation Solution
A heat exchanger design featuring a tubular upper and lower header with a gap between them, fins between the tubes, and adhesive damping materials on the headers, where the damping materials extend between the headers and buffer materials to prevent peeling, with a condensate water discharge unit to manage condensate water effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If damping material is used to suppress noise, then noise is reduced, but adhesive force decreases due to condensate water or aging causing the damping material to peel off
Solution Approach 1:
The buffer material serves as an intermediary component between the damping material and the heat exchanger body. It provides mechanical support to the damping material at both end portions, preventing peeling while maintaining noise suppression functionality. The buffer material transfers and distributes the adhesive forces, reducing the stress concentration on the damping material's adhesive layers.
Solution Approach 2:
The buffer material is positioned beforehand at both end portions of the heat exchanger body to provide preventive support. This prior cushioning structure compensates for the potential loss of adhesive force due to condensate water or aging, ensuring the damping material remains securely attached throughout its service life.
2Reliability
If buffer material is provided to cover the entire heat exchanger body, then damping material peeling is prevented, but material usage and cost increase
Solution Approach 1:
Instead of uniformly covering the entire heat exchanger body with buffer material, the invention applies buffer material selectively only at both end portions where the damping material is most prone to peeling. This localized application maintains reliability where needed while minimizing material usage and cost in areas where it is less critical.
Solution Approach 2:
The buffer material coverage is segmented into discrete locations (both end portions) rather than continuous coverage. This segmentation strategy focuses the buffer material's support function where it is most needed to prevent damping material peeling, reducing overall material consumption while maintaining effectiveness.
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
Prevents the damping material from peeling off, reducing noise and vibration while minimizing the use of buffer materials, thus lowering costs.
Implementation Method 1
it is possible to support a portion of each of both end portions of the lower damping material using the lower buffer materials supported by the first and second abutment portions
Implementation Method 2
an adhesive lower damping material which is provided on the lower outer peripheral surface of the lower header exposed from the lower buffer material
Implementation Method 3
a condensate water discharge unit which is provided below the first and second abutment portions and discharges condensate water attached to the heat exchanger body to an outside
Implementation Method 4
air-conditioning air introduced in the casing and the refrigerant flowing through the tubes of the heat exchanger body are heat-exchanged with each other
Implementation Method 5
fins which are provided between the tubes provided at positions adjacent to each other
Data Source
AI summary
A heat exchanger includes: a heat exchanger body which includes an adhesive lower damping material which is provided on a lower outer peripheral surface of a lower tubular member exposed from a lower buffer material provided in each of both end portions in both end portions of the lower tubular member constituting at least a lower header and is formed such that at least a portion of each of both end portions extends between the lower tubular member and the lower buffer material; and a casing which includes first and second abutment portions against which the lower buffer material abuts and a condensate water discharge unit which discharges condensate water to an outside.