Heat Exchanger Support Frame Inclined Rim Sealing
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Solution Overview
Problem
Existing heat exchanger sealing systems in motor vehicles, particularly in hybrid and electric vehicles, face challenges with air leakage due to high overpressure during rapid charging, which reduces thermal performance, and are complicated by the variety of pipe diameters and difficult assembly/disassembly processes.
Innovation Solution
A front end module with a support frame featuring a slot and inclined rims that guide the flange of the heat exchanger for angled insertion and pivoting, ensuring a sealed assembly without additional elastomer-based sealing elements, simplifying the assembly process and maintaining hermetic encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing devices made of elastomer are used to seal around pipes of varying diameters, then sealing effectiveness is improved, but device complexity and assembly difficulty increase due to the need for custom dimensions and overmolding operations
Solution Approach 1:
The frame structure is designed with a universal sealing mechanism that can accommodate pipes of varying diameters without requiring custom sealing devices. The frame's geometry and positioning system provide adaptability to different pipe sizes while maintaining consistent sealing performance, eliminating the need for multiple specialized sealing components.
Solution Approach 2:
The sealing function is extracted from separate elastomer-based sealing devices and integrated directly into the frame structure itself. This eliminates the need for additional sealing components and their complex assembly operations, while the frame's design inherently provides the sealing capability through its geometric features and positioning mechanisms.
2Reliability
If elastomer-based sealing devices are used to ensure hermetic encapsulation, then sealing effectiveness is improved, but ease of repair and disassembly deteriorate due to permanent attachment requirements
Solution Approach 1:
The sealing function is extracted from permanent elastomer attachments and integrated into the frame structure through geometric features. This allows the frame to provide hermetic encapsulation while maintaining mechanical reversibility, enabling easy disassembly for repair or maintenance without compromising sealing effectiveness.
Solution Approach 2:
The sealing mechanism transitions from a static, permanent elastomer attachment to a dynamic system where the frame's geometric features can accommodate assembly and disassembly. The frame structure allows for reversible positioning and sealing, enabling maintenance operations while maintaining hermetic encapsulation during operation.
3Reliability
If sealing devices are installed close to passage openings to prevent air leakage, then sealing effectiveness is improved, but device complexity increases due to the need for precise positioning and integration with the frame
Solution Approach 1:
The sealing function is merged with the frame structure itself rather than being implemented as a separate component. The frame's geometric features and positioning system are integrated to provide sealing close to passage openings, eliminating the need for additional sealing devices and their complex integration processes.
Solution Approach 2:
The sealing capability is extracted from separate sealing devices and embedded into the frame structure through its geometric design. This integration provides air leakage prevention at critical locations while simplifying the overall system by eliminating separate sealing components and their complex positioning requirements.
Data Source
AI summary
Support frame (4) configured to bear a heat exchanger comprising a flange (22) for coolant to pass through, the frame comprising a lateral wall (12) in which a light (28) is produced, which is configured to be passed through by the flange (22), characterized in that the lateral wall (12) comprises at least one edge (34, 36) placed near an end of the light (28) and arranged at least partially through the light (28) so as to define an insertion path for the flange which is inclined relative to the normal to the lateral wall, the edge also being configured to form a point on which the flange pivots.