Modular Heat Exchanger Cassettes for Vehicle HVAC Adaptability

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Solution Overview

Problem

Existing air conditioning systems for vehicles with internal combustion engines, hybrid drives, and electric drives require different heating elements, leading to incompatible size and arrangement issues, necessitating separate air conditioning housing types, which are costly and inefficient.

Innovation Solution

A modular heat exchanger unit with interchangeable cassettes that accommodate various heat exchanger modules, allowing for flexible configuration and adaptation to different vehicle types and climate conditions, enabling optimal heat exchange without the need for multiple housing variants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different heating elements are used for vehicles with internal combustion engines, hybrid drives, and electric drives, then the heating elements can be optimized for specific vehicle types, but the size and arrangement become incompatible, necessitating separate air conditioning housing types

Engineering Contradiction:

Improveadaptability to different vehicle typesVSAvoidnumber of housing variants

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heating element assembly is segmented into modular components that can be independently configured. Different heating elements (glycol heater, PTC heater, high-volt PTC heater) are designed as separate modules that can be selectively combined and arranged in different sequences within a single housing, eliminating the need for multiple housing variants.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal housing design is created that can accommodate multiple types of heating elements through standardized mounting positions and connection interfaces. The housing structure includes multiple possible mounting locations for heating elements, allowing the same housing to serve different vehicle types by simply reconfiguring which heating elements are installed and in what sequence.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If fixed size and arrangement of heating elements are used, then the air conditioning housing can be simplified, but the system cannot be used for different vehicle types such as internal combustion engine, hybrid drive, or electric drive

Engineering Contradiction:

Improvehousing structureVSAvoidcompatibility with different vehicle types

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The heating element arrangement is made dynamic and reconfigurable rather than fixed. The housing includes multiple mounting positions and adjustable support structures that allow heating elements to be positioned at different locations and in different sequences depending on the vehicle type requirements, while maintaining a simplified single housing structure.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If multiple housing variants are created for different vehicle types, then compatibility with different vehicle types is achieved, but the cost and manufacturing complexity increase

Engineering Contradiction:

Improvecompatibility with different vehicle typesVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single universal housing design is developed that can be manufactured in large volumes for all vehicle types, reducing per-unit manufacturing costs. The housing incorporates standardized features and mounting points that allow different heating element configurations without requiring different housing variants, thereby simplifying production and reducing tooling costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the functionality of multiple vehicle-specific housings into a single multi-functional housing design. By combining the accommodation capabilities for different heating element types and arrangements into one housing structure, the need for separate manufacturing lines and inventories of different housing variants is eliminated.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables simple, economical, and space-saving interchangeability of heat exchanger modules, optimizing their use across different vehicle types and conditions, reducing energy input and flow noise while maximizing overall efficiency.

Implementation Method 1

heat exchanger modules which can be inserted into the heat exchanger unit and interchanged with each other in sequence in the air flow direction

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

auxiliary electrical heater, such as a positive temperature coefficient (PTC) heating element

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS9823023B2Heat exchanger unit with removable cassettes for air conditioning in motor vehicles

Publication Date: 2017.11.21 HANON SYST CO LTD

AI summary

A heat exchanger unit that enables a quick interchanging of function, form and size of the different heat exchanger modules. The interchanging may be possible in regard to the sequence of the individual heat exchanger modules. The heat exchanger unit in includes inserts configured such that appropriately configured cassettes can be inserted, and an inner shape of the cassettes is configured so that different heat exchanger modules can be accommodated therein. The cassettes are thus designed specific to the heat exchanger, while the outer shape of all cassettes conforms to the shape of the uniformly configured inserts.