Heat Exchanger Casing with Convex Stress Absorption Zone
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Solution Overview
Problem
Existing heat exchangers for motor vehicle engine air supply circuits face mechanical stress issues due to boost pressure, which can exceed the material's limits, leading to potential deformation and increased manufacturing costs when trying to reduce material thickness for stress resistance.
Innovation Solution
Incorporating stress absorption zones, such as convex surfaces and stiffening means, into the casing of the heat exchanger adjacent to the fluid inlet header tank to distribute and manage mechanical stresses, allowing for thinner materials while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the casing material is increased to withstand mechanical stresses from boost pressure, then the strength and stress resistance of the casing is improved, but the manufacturing cost increases and the device becomes heavier
Solution Approach 1:
The patent applies local quality by creating stress absorption zones with convex surfaces at specific locations on the casing where mechanical stresses are highest. Instead of uniformly increasing material thickness throughout the entire casing, the convex surfaces are strategically positioned to provide localized reinforcement. This allows the casing to withstand boost pressure effectively while maintaining thinner material in other areas, thereby reducing overall material consumption and manufacturing cost.
Solution Approach 2:
The patent utilizes spheroidality by incorporating convex surfaces (curved geometries) into the casing structure at stress absorption zones. These convex surfaces distribute mechanical stresses more effectively across the material compared to flat surfaces, enhancing the casing's ability to withstand boost pressure. The curved geometry allows for more efficient stress distribution, enabling the use of thinner materials while maintaining structural integrity.
2Strength
If the thickness of the casing material is increased to withstand mechanical stresses, then the strength of the casing is improved, but the device complexity and additional components increase
Solution Approach 1:
The patent applies merging by integrating the stress absorption zones directly into the casing structure itself, rather than adding separate reinforcement components. The convex surfaces are formed as part of the casing's geometry, combining the structural function of the casing with the stress management function in a single integrated component. This eliminates the need for additional separate parts and simplifies the overall device complexity.
Solution Approach 2:
By applying local quality through strategically positioned convex surfaces, the patent provides reinforcement only where mechanically necessary. This localized approach avoids the need for comprehensive thickening of the entire casing or addition of numerous reinforcement components throughout the structure, thereby maintaining simplicity while achieving the required strength.
3Ease of manufacture
If the material thickness is reduced to lower manufacturing costs, then the ease of manufacture is improved, but the ability to withstand mechanical stresses deteriorates
Solution Approach 1:
The patent resolves this contradiction by applying local quality through convex surfaces at stress absorption zones. These localized geometric features provide enhanced stress resistance precisely where mechanical loads are highest, allowing the use of thinner materials in other areas. This enables cost-effective manufacturing with reduced material thickness while maintaining adequate strength through strategic local reinforcement.
Solution Approach 2:
By incorporating convex surfaces with curved geometries at critical stress points, the patent enables the use of thinner materials overall. The curvature distributes stresses more efficiently, compensating for the reduced material thickness in a cost-effective manner that maintains structural integrity while reducing manufacturing costs.
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 heat exchanger effectively withstands mechanical stresses with reduced material thickness, enhancing its rigidity and ability to cool supercharged charge air efficiently, while minimizing manufacturing costs.
Implementation Method 1
said at least one absorption zone has at least one convex surface, the convex face facing in the general direction of stress
Implementation Method 2
a core bundle for exchanging heat between fluids... allows the supercharged engine charge air to be cooled by exchange of heat with another fluid such as external air or a liquid such as the water from the engine cooling circuit
Data Source
AI summary
A heat exchanger for an automotive vehicle includes a core bundle for exchanging heat between fluids, a case for housing the core bundle, a container for collecting inlet fluid, and a container for collecting outlet fluid. The case presents at least an area for absorbing stress, adjacent to the inlet collection container, such that the case withstands mechanical stress exerted on the case when the fluid flows in the core bundle from the fluid inlet container to the fluid outlet container.