Intercooler Collar Gasket Integration for Compact Dimensions
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Solution Overview
Problem
Existing heat exchangers for motor vehicles are not compact enough, as they require larger dimensions to maintain performance.
Innovation Solution
A heat exchanger design featuring parallel pipes with metal bottom plates of constant thickness, clinched plastic manifold tanks, and a rectangular annular gasket that integrates the collar walls as the gasket seat, reducing overall dimensions without compromising performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional heat exchanger design is used with separate collar and gasket seat structures, then manufacturing and assembly are simplified, but the overall dimensions become larger and less compact
Solution Approach 1:
The collar and gasket seat structures are merged into a single integrated collar component. The collar includes both the pipe retention function and the gasket seating surface, eliminating the need for separate structures. This integration directly reduces the overall dimensions of the heat exchanger while maintaining the necessary functional complexity through clever structural design.
Solution Approach 2:
The collar is designed as a multi-functional component that simultaneously performs pipe retention, gasket support, and sealing functions. By making the collar universal in its functions, the design eliminates redundant structures and reduces overall dimensions without compromising manufacturing simplicity or assembly ease.
2Volume of moving object
If the distance between pipes and gasket is increased for manufacturing tolerance, then assembly is easier, but the heat exchanger becomes less compact
Solution Approach 1:
The collar is designed with locally optimized features including an enlarged portion that provides a dedicated gasket seat with specific dimensional tolerances. This localized precision feature ensures proper gasket positioning and sealing while allowing the rest of the structure to maintain compact dimensions. The local quality enhancement at the gasket interface compensates for the reduced overall tolerances enabled by compact design.
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 design achieves a significant reduction in overall dimensions while maintaining performance, making it more compact than traditional heat exchangers.
Implementation Method 1
an annular gasket of a substantially rectangular shape, which surrounds the aforesaid collars and is compressed between a seat of the bottom plate and a rim of the manifold tank
Implementation Method 2
A heat exchanger, in particular an intercooler for motor vehicles
Implementation Method 3
a plurality of pipes parallel to one another, a metal bottom plate formed by a metal plate of constant thickness sheared and bent
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Described herein is a heat exchanger, in particular an intercooler for motor vehicles, comprising: - a plurality of pipes (12) parallel to one another; - a metal bottom plate (14) formed by a metal plate of constant thickness (T) sheared and bent and having a plurality of collars (20), inserted within which are the ends of the respective pipes (12); - a manifold tank made of plastic material (16) fixed by clinching to the bottom plate (14); and - an annular gasket (28) compressed between an outer rim (36) of the manifold tank (16) and a base surface (22) of the bottom plate (14). The distance between the outer surface of the pipes (12) and the gasket (28) is equal to the thickness of the walls (20b) of said collars (20).