Modular Heat Exchanger with Alternative Connection Elements
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Solution Overview
Problem
The increasing complexity of motor vehicle drive trains, particularly in hybrid vehicles, necessitates a more cost-effective and space-efficient integration of coolant pumps and other functional elements into internal combustion engine cooling systems, as downsizing reduces available housing space and increases the number of variants.
Innovation Solution
A modular heat exchanger design with multiple connection elements that can be alternately connected to a common interface, allowing for the integration of different functional elements such as coolant pumps, mixing valves, or temperature sensors, with quick-coupling functionality and sealing elements for efficient and versatile use across various vehicle variants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the displacement volume and number of cylinders in combustion engines are reduced (downsizing), then fuel efficiency and emissions are improved, but the available surface area for attaching auxiliary components is reduced
Solution Approach 1:
The patent combines the heat exchanger box with the coolant pump housing into a single integrated component. The heat exchanger box serves dual functions as both a thermal management component and a mounting structure for the coolant pump, thereby eliminating the need for separate mounting space on the cylinder block and resolving the space constraint imposed by engine downsizing.
Solution Approach 2:
The heat exchanger box is designed with multi-functionality, serving as both a heat exchange component and a structural mounting platform for the coolant pump. This universal design allows the same component to fulfill multiple roles, compensating for the reduced available space in downsized engines.
2Adaptability or versatility
If the number of vehicle variants is increased to meet diverse customer requirements, then market adaptability is improved, but the number of individual cooling system components that must be manufactured separately increases
Solution Approach 1:
The integrated heat exchanger box and coolant pump assembly serves as a universal module that can be applied across multiple vehicle variants. The standardized connection interface and modular design allow this single component configuration to satisfy different cooling system requirements without necessitating separate component designs for each variant.
Solution Approach 2:
The cooling system is segmented into modular components with standardized interfaces. The heat exchanger box with integrated coolant pump forms one module that can be independently configured and combined with other standardized cooling components, enabling flexible assembly for different vehicle variants while maintaining manufacturing efficiency.
3Volume of moving object
If coolant pumps are integrated directly into the heat exchanger box, then space usage is optimized, but manufacturing complexity and variant-specific customization requirements increase
Solution Approach 1:
The coolant pump is integrated directly into the heat exchanger box, with the pump housing forming part of the heat exchanger box structure. This merging optimizes space utilization by eliminating gaps and separate mounting structures, while the standardized integration method keeps manufacturing complexity manageable through modular assembly.
Data Source
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AI summary
A heat exchanger (36), which comprises a plurality of heat exchanger pipes which are provided for throughflow by means of a cooling liquid, and at least two heat exchanger boxes (40, 42) which are connected to the heat exchanger pipes at opposite ends, wherein at least one of the heat exchanger boxes (42) forms a connection opening (52), which integrates into a connection interface (50) for connecting to a connection element, can be combined with a plurality of functionally different connection elements which can be alternatively connected to the connection point (50) in a fluid-conducting manner with the connection opening (52). Same allows the heat exchanger (36) to be configured as a base module which is not to be changed as much as possible, which, depending on the variant to be realised, is combined with one of a plurality of connection elements integrating the differences that define the variants.