Perpendicular Heat Exchanger Overlap for Compact Cooling
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Solution Overview
Problem
Existing cooling assemblies for motor vehicles face challenges in reducing size while maintaining thermal performance, often leading to collisions between heat exchangers that result in noise, vibrations, or system malfunction.
Innovation Solution
A cooling assembly design featuring a primary and secondary heat exchanger arranged in parallel and perpendicular to each other, with overlapping header plates to minimize space and prevent collisions, and a detachable locking mechanism to secure the heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If heat exchangers are arranged in parallel and perpendicularly with overlapping header plates, then the overall size of the cooling assembly is reduced, but the risk of collision between heat exchangers increases
Solution Approach 1:
The secondary header plates are positioned to overlap the stack of primary tubes, creating a nested arrangement where one heat exchanger component is positioned within the spatial envelope of another. This nesting approach allows the heat exchangers to be arranged perpendicularly in parallel, maximizing space utilization while preventing collision between the heat exchanger bodies
Solution Approach 2:
The heat exchangers are arranged in perpendicular directions rather than parallel alignment, transitioning from a one-dimensional linear arrangement to a two-dimensional orthogonal configuration. This dimensional change allows overlapping header plates to serve both as structural connection points and as collision barriers, reducing overall assembly volume while maintaining reliability
2Area of stationary object
If the distance between heat exchangers is decreased to reduce module dimensions, then packaging space is optimized, but collisions between heat exchangers may occur resulting in noise, vibrations or system malfunction
Solution Approach 1:
The overlapping header plates are designed to extend beyond the tube stacks, creating a protective overlap region before the heat exchanger bodies could potentially collide. This beforehand cushioning arrangement ensures that even at minimal distances, the header plates serve as buffer zones that prevent direct contact between the heat exchanger components, eliminating noise, vibrations, and malfunction risks
3Temperature
If heat exchangers are made of metal components assembled with synthetic components, then thermal performance is improved, but the complexity of assembly and material usage increases
Solution Approach 1:
The header plates of different materials (metal and synthetic) are merged into a single integrated component structure that serves both thermal exchange and structural support functions. This merging approach eliminates the need for separate assembly steps for metal and synthetic components, reducing assembly complexity while maintaining the thermal performance benefits of metal heat exchange surfaces
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
This design effectively reduces the overall size of the cooling assembly, minimizes the risk of heat exchanger collisions, and enhances thermal performance, while also simplifying installation and reducing material usage.
Implementation Method 1
a primary heat exchanger comprising a pair of primary collector boxes, the primary collector boxes with primary header plates, the primary header plates being of essentially rectangular shape; a plurality of primary tubes stacked between the primary header plates; a secondary heat exchanger comprising a pair of secondary collector boxes with secondary header plates
Data Source
AI summary
A cooling assembly for a motor vehicle, the cooling assembly having a primary heat exchanger comprising a pair of primary collector boxes, the primary collector boxes with primary header plates, the primary header plates being of essentially rectangular shape; a plurality of primary tubes stacked between the primary header plates; a secondary heat exchanger comprising a pair of secondary collector boxes with secondary header plates being of essentially rectangular shape; a plurality of secondary tubes stacked between the secondary collector boxes. The primary heat exchanger and the secondary heat exchanger are arranged in parallel, perpendicularly to each other so that the secondary header plates of the secondary heat exchanger at least partially overlap the stack of the primary tubes of the primary heat exchanger.