Heat Exchanger Array Assembly for Thermal Expansion and Leak Control
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Solution Overview
Problem
Existing heat exchanger integration in motor vehicles faces challenges such as high complexity, precision tooling costs, assembly issues, thermal expansion leading to fluid leakage, and performance degradation due to common plates limiting thermal expansion and providing inadequate insulation between cores.
Innovation Solution
A heat exchange array with puzzle plates fixed to cores, allowing immobilization in specific directions and using projections and nests for frictional connections, along with a baseplate for structural support, to manage thermal expansion and insulation between heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If heat exchangers are integrated closely together to reduce size and cost, then integration level and compactness are improved, but thermal expansion differences cause cracks and fluid leakage
Solution Approach 1:
The patent divides the mounting structure into separate puzzle plates for each heat exchanger core, allowing independent thermal expansion of each core while maintaining overall integration. Each core has its own puzzle plate that accommodates expansion movements without affecting neighboring cores.
Solution Approach 2:
The patent introduces puzzle plates as intermediary components between the heat exchanger cores and the baseplate. These puzzle plates act as buffers that absorb thermal expansion stresses, preventing direct stress transmission to the cores and eliminating crack formation.
2Device complexity
If common plates are used to connect heat exchanger cores, then integration is improved, but thermal expansion is limited causing cracks and leakage
Solution Approach 1:
Instead of using a single common plate to connect all cores, the patent segments the connection structure into individual puzzle plates for each core. This segmentation allows each core to expand independently without being constrained by a rigid common plate structure.
Solution Approach 2:
The puzzle plates incorporate dynamic features such as protrusions and nests that allow for movement and adjustment during thermal expansion. This dynamic design enables the structure to adapt to changing dimensions while maintaining connections.
3Device complexity
If common plates are used to connect cores, then integration is improved, but thermal insulation between cores is insufficient leading to performance degradation
Solution Approach 1:
The patent segments the connection structure into separate puzzle plates for each core, which naturally provides thermal insulation between cores. The individual puzzle plates act as thermal barriers, preventing unwanted heat transfer while maintaining mechanical integration.
Solution Approach 2:
The puzzle plates serve as intermediary components that provide both mechanical connection and thermal insulation. The material and structure of the puzzle plates are designed to minimize thermal conductivity between adjacent cores while maintaining structural integrity.
4Manufacturing precision
If precision tooling is used to assemble integrated heat exchangers, then assembly precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the assembly into modular components (cores, puzzle plates, baseplate) that can be manufactured separately using standard tooling. This modular approach reduces the need for expensive precision tooling while maintaining assembly precision through the self-aligning puzzle plate design.
Solution Approach 2:
The puzzle plates incorporate asymmetric protrusions and nests that provide self-aligning features during assembly. This asymmetric design guides the assembly process and ensures proper positioning without requiring high-precision tooling or complex alignment procedures.
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
The solution effectively minimizes thermal transfer and leakage by stabilizing the arrangement of heat exchangers, reducing complexity and costs while maintaining performance.
Implementation Method 1
using the common plate the expansion of at least one of the cores may be limited, leading to cracks therein and consequently, leakage
Implementation Method 2
when two or more heat exchangers arranged very close to each other are subject to different rates of thermal expansion and/or contraction as the heat exchangers may operate in different modes and in different fluids
Data Source
Figure 1~2
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Figure 5
AI summary
The object of the invention is, inter alia, a heat exchange array (1000) for a motor vehicle comprising a first heat exchanger (100) comprising a first core (105) for a circulation of at least first fluid therein, the first core (105) comprising a plurality of first heat exchange elements (105a) stacked in a first stacking direction, and at least one second heat exchanger (200) for circulation of at least second fluid therein, the second heat exchanger (200) further comprising a second core (205) comprising a plurality of second heat exchange elements (205a) stacked in a second stacking direction, the second stacking direction being substantially parallel with respect to the first stacking direction, wherein the cores (105, 205) are fixed directly to a baseplate (500), wherein the array (1000) further comprises a first puzzle plate (150) fixed to the first core (105) so that the first core (105) is sandwiched between the first puzzle plate (150) and the baseplate (500), and the second puzzle plate (250) fixed to the second core (205) so that the second core (205) is sandwiched between the second puzzle plate (250) and the baseplate (500), wherein the puzzle plates (150, 250) are configured to at least partially immobilize the second heat exchanger (200) with respect to the first heat exchanger (100) in at least a third direction, the third direction being normal at least to the first stacking direction.