Multi-Heat Exchanger Assembly With Pivoted Parallel Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling assemblies in motor vehicles face challenges in reducing production costs and weight while maintaining thermal performance, as current solutions primarily focus on reducing the size of individual components without addressing the overall cost and weight reduction of multiple heat exchangers.
Innovation Solution
A cooling assembly design that integrates multiple heat exchangers with innovative fixation methods, including pivoting and parallel alignment, using U-shaped and L-shaped supports, clips, and tensioners to secure heat exchangers, allowing for efficient assembly and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of heat exchangers is reduced to improve packaging, then packaging efficiency is improved, but thermal performance deteriorates
Solution Approach 1:
The patent combines multiple heat exchangers into a single integrated assembly with shared manifolds and tubes. Instead of using separate heat exchanger units, the invention merges their functional components (manifolds, tubes, headers) into one unified structure that achieves both compact size and adequate thermal performance through optimized fluid distribution across multiple exchange surfaces.
2Ease of manufacture
If synthetic components are used to reduce production cost, then manufacturing cost is improved, but weight increases
Solution Approach 1:
The patent employs a composite construction where aluminum manifolds (metal) are integrated with plastic headers and synthetic components. This composite approach allows the use of lightweight synthetic materials for non-critical components (reducing overall weight and production cost) while retaining metal materials where structural strength and thermal conductivity are essential, thus balancing cost and weight requirements.
3Volume of moving object
If multiple heat exchangers are assembled closely to reduce dimensions, then overall dimensions are improved, but assembly complexity increases
Solution Approach 1:
The patent segments the cooling assembly into modular functional units (different heat exchanger sections) that are interconnected through a standardized manifold-tube-header architecture. This segmentation allows each module to be designed and assembled independently, then integrated into the complete assembly, reducing overall complexity compared to a fully integrated monolithic design while achieving compact dimensions.
4Weight of moving object
If material usage is reduced to decrease weight, then weight is improved, but production cost may increase due to manufacturing constraints
Solution Approach 1:
The patent optimizes material usage by changing design parameters such as wall thickness, component geometry, and material selection for different parts. By carefully adjusting these parameters, the assembly achieves reduced weight through minimized material consumption while maintaining manufacturing feasibility and cost-effectiveness through optimized production processes for the reduced material volumes.
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 cost-effective and lightweight cooling assemblies with improved thermal performance by optimizing the assembly process of multiple heat exchangers, reducing material waste and fuel consumption.
Implementation Method 1
a cooling assembly configured to provide a heat exchange between the fluids
Implementation Method 2
The sub-components responsible for heat exchange, such as the heat exchanger core comprising tubes assembled with the headers
Implementation Method 3
Heat exchangers in motor vehicles are usually responsible for thermal management of the powertrain, the air conditioning system
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cooling assembly (1) configured to provide a heat exchange between the fluids comprising: at least one first heat exchanger (100) comprising a pair of first manifolds (11, 12) comprising an axis of elongation of the first manifolds (M1), and a plurality of first tubes (15) stacked between the first manifolds (11,12), each first tube (15) comprising an axis of elongation of the first tubes (T1) which is substantially perpendicular to axis of elongation of the first manifolds (M1), wherein the axes (T1, M1) form the general plane (P1) of the first heat exchanger (100), at least one second heat exchanger (200) comprising a pair of second manifolds (21, 22) comprising an axis of elongation of the second manifolds (M2), and a plurality of second tubes (25) stacked between the second manifolds (21,22), each second tube (25) comprising an axis of elongation of the second tubes (T2) which is substantially perpendicular to axis of elongation of the second manifolds (M2), wherein the axes (T2, M2) form the general plane (P2) of the second heat exchanger (200), at least one third heat exchanger (300) comprising a pair of third manifolds (31, 32) comprising an axis of elongation of the third manifolds (M3), and a plurality of third tubes (35) stacked between the third manifolds (31,32), each third tube (35) comprising an axis of elongation of the third tubes (T3) which is substantially perpendicular to axis of elongation of the third manifolds (M3), wherein the axes (T3, M3) form the general plane (P3) of the third heat exchanger (300), characterised in that the second heat exchanger (200) is adapted to be fixed to the first heat exchanger (100) at least by pivoting thereof around an axis of elongation of the second manifold (M2) until the general plane (P2) of the second heat exchanger (200) is parallel to the general plane (P1) of the first heat exchanger (100), and in that the third heat exchanger (300) is adapted to be fixed to the first heat exchanger (100) along the axis perpendicular to the general planes (P1, P2) of the heat exchangers (100, 300) by at least pushing the third heat exchanger (300) towards the first heat exchanger (100) so that the planes (P1, P2) remain parallel with respect to each other during and after fixing one heat exchanger (300) to the other (100).