Integrated Fluid Connection Device for Vehicle Heat Exchanger Assembly
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Solution Overview
Problem
Existing motor vehicle heating, ventilation, and air conditioning installations face challenges in simplified assembly and sealing of heat exchangers, often requiring expensive materials and tools, leading to increased costs and assembly effort.
Innovation Solution
The integration of a connection device directly into the cover and housing of the heat exchanger, eliminating the need for additional connecting pieces or tools, using complementary half-flanges and a hinge for secure assembly and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal collar is used to connect pipes to the heat exchanger, then sufficient flexibility and rigidity are achieved to allow assembly and prevent extraction, but the material cost increases significantly
Solution Approach 1:
The patent replaces expensive metal collars with a plastic connection device that integrates the sealing and connecting functions. The plastic material is molded into a specific shape with a radially extendable section that can be inserted into the heat exchanger housing and expanded to secure the pipe connection, eliminating the need for costly metal components while maintaining connection strength
Solution Approach 2:
The connection device utilizes the elastic properties of plastic material, changing its physical state from a compressed storage form to an expanded installed form. The radially extendable section is designed to be compressed during assembly and then expand radially to engage with the housing and secure the pipe, providing both flexibility for assembly and rigidity for support without requiring expensive materials
2Strength
If pipes are crimped on the connection ends, then a secure connection is achieved, but expensive specialized tools are required increasing assembly cost
Solution Approach 1:
The connection device is designed to perform its own installation without requiring external specialized tools. The radially extendable section is inserted in a compressed state through the housing opening, then expanded manually or with simple tools to engage with the housing structure and secure the pipe connection, eliminating the need for expensive crimping equipment
Solution Approach 2:
The connection device is divided into functional sections: a mounting section that engages with the heat exchanger housing, a radially extendable section that provides the expanding connection mechanism, and a pipe engagement section that secures the pipe. This segmentation allows each part to be optimized for its specific function and assembled in a straightforward sequence without complex tooling
3Reliability
If additional connection devices are added to ensure sealing, then sealing performance is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The connection device merges multiple functions into a single integrated component: the mounting function (engaging with the housing), the sealing function (providing a seal between the pipe and heat exchanger connection end), and the securing function (preventing pipe extraction). This consolidation eliminates the need for separate sealing elements and connection hardware, reducing part count while improving reliability
Solution Approach 2:
The radially extendable section serves multiple purposes: it provides the structural connection between the pipe and housing, creates a sealing interface through its radial expansion against the housing and pipe, and acts as a locking mechanism to prevent disassembly. This multi-functionality in a single component simplifies the overall assembly while ensuring reliable sealing and connection
Data Source
Figure 1~2a
Figure 2b~2c
Figure 3~4
AI summary
The invention concerns an installation for a motor vehicle comprising: - a heat exchanger, - a casing (7) for receiving the heat exchanger, having at least one opening for inserting the heat exchanger, - a cover (11) arranged facing the opening in the casing (7), - at least two inlet and outlet tubes (3a, 3b) for a fluid, intended to be connected to a fluid circuit, and - a connection device (29, 31) for connecting the fluid inlet and outlet tubes (3a, 3b) to the heat exchanger. According to the invention, the connection device (29, 31) is formed by the cover (11) and by the casing (7).