Heat Exchanger Sealing Frame to Minimize Airflow Bypass
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Solution Overview
Problem
Conventional heat exchanger modules suffer from gaps between the frame and manifold, leading to reduced thermal performance due to airflow bypass, and existing sealing methods using foam or glue are environmentally detrimental and increase production complexity.
Innovation Solution
A sealing frame with a U-shaped first portion and closing portion is designed to contact all sides of the heat exchanger, incorporating straight ribs to redirect airflow and clips to stabilize the heat exchanger, reducing gaps and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam is glued to the sides of the heat exchanger to seal gaps, then sealing effectiveness is improved, but environmental harm increases and reliability deteriorates
Solution Approach 1:
The patent removes the harmful sealing materials (foam and glue) from the system entirely. Instead, it uses a mechanical sealing frame structure that provides sealing functionality without requiring adhesive materials, thereby eliminating environmental harm while maintaining sealing reliability
Solution Approach 2:
The sealing frame acts as an intermediary component between the heat exchanger and the surrounding structure. It provides the sealing function mechanically through its frame structure and sealing elements, replacing the need for foam and glue while improving reliability through a more stable connection
2Reliability
If foam is glued to the heat exchanger sides, then sealing is achieved, but production complexity increases
Solution Approach 1:
The patent combines the sealing function with the structural frame into a single integrated component. The sealing frame is designed as one piece that provides both structural support and sealing functionality, eliminating the need for separate foam application and glue bonding steps, thereby reducing production complexity while maintaining sealing effectiveness
Solution Approach 2:
The sealing frame is designed to self-align and self-seal through its geometric features. The frame includes guiding elements and sealing surfaces that automatically position and seal against the heat exchanger during assembly, eliminating the need for complex alignment procedures and multiple sealing materials
3Reliability
If multiple components are used to connect the heat exchanger, then connection stability is improved, but production time increases
Solution Approach 1:
The patent merges multiple connection and sealing functions into a single sealing frame component. This integrated frame provides both structural connection and sealing in one element, reducing the number of parts and assembly steps while maintaining connection stability through its robust frame structure and mounting features
Solution Approach 2:
The sealing frame is designed as a modular component that can be easily installed as a single unit. Its segmented design allows for simple attachment to the heat exchanger and surrounding structure, reducing assembly time while maintaining stability through its distributed mounting points and rigid frame construction
Data Source
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AI summary
The present invention provides a module for a motor vehicle,. The module includes a heat exchanger for a heat exchange between the first fluid and a second fluid and a sealing frame. The heat exchanger includes a pair of manifolds, and heat exchange elements stacked between the manifolds to enable first fluid flow in-between the heat exchange elements. Further, the manifolds includes an outer surface facing away from the stack of heat exchange tubes. The sealing frame is extending away from the stack of heat exchange element and the outer surface of the manifolds to prevent the first fluid flowing from at least in the vicinity of the manifold. The sealing frame includes an essentially U-shaped portion adapted to be fixed to the heat exchanger and a closing portion adapted to couple to an open end of the U-shaped portion.