Plastic Air Distributor with Integrated Heat Exchanger
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Solution Overview
Problem
Conventional air distributors with integrated heat exchangers suffer from bulkiness, bypass effects, and inefficient heat transfer due to their parallelepiped shape, as well as lengthy manufacturing processes requiring screws and bolts for mechanical strength.
Innovation Solution
A plastic air distributor design featuring two half-shells and a stack of plastic plates, where the plates are fixed to each other and the half-shells, eliminating the need for screws and bolts, and incorporating interlocking means and deflecting elements to prevent bypass and optimize heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional stacked plate heat exchanger with aluminum plates and screws is used, then mechanical strength is ensured, but the device becomes bulky and manufacturing time increases
Solution Approach 1:
The patent merges the heat exchanger plates with the air distributor housing into a single integrated plastic component. The housing itself forms the external parallelepiped shape while internally containing the stacked plate heat exchanger structure, eliminating the need for separate metal housing and reducing overall device volume while maintaining mechanical strength through the plastic integration
Solution Approach 2:
The patent uses plastic material (specifically polyamide or similar engineering plastic) to replace traditional aluminum plates and metal housing. The plastic material provides both the structural strength needed for pressure containment and the heat exchange functionality, creating a composite solution that is lighter and more compact than traditional metal-based designs
2Ease of manufacture
If gaps are left between the heat exchanger and manifold, then assembly is easier, but bypass effect occurs reducing heat exchange efficiency
Solution Approach 1:
The patent applies different surface characteristics to different regions of the heat exchanger plates. The outer surfaces of the plates that contact the housing are made substantially flat to ensure tight sealing and prevent bypass flow, while the inner surfaces maintain the corrugated or ribbed structure needed for heat exchange. This local differentiation of surface quality prevents energy loss without compromising assembly
Solution Approach 2:
The patent introduces sealing elements or gaskets as intermediary components between the heat exchanger plates and the housing. These sealing intermediaries fill any potential gaps and prevent bypass flow of air, ensuring that all air passes through the heat exchange channels while maintaining ease of assembly through simple insertion and sealing
3Stress or pressure
If screws and bolts are added to ensure mechanical strength, then pressure resistance improves, but manufacturing process length increases
Solution Approach 1:
The patent combines the housing and heat exchanger into a single molded plastic component, eliminating the need for separate fastening elements like screws and bolts. The integration is achieved through injection molding or similar plastic forming processes that create the complete assembly in one manufacturing step, drastically reducing manufacturing time while maintaining pressure resistance through the monolithic plastic structure
Solution Approach 2:
The patent replaces the mechanical fastening system (screws, bolts, and associated assembly steps) with a chemical bonding approach through plastic molding. The plastic material itself provides the structural integrity and pressure containment that would otherwise require mechanical fasteners, substituting a chemical/thermal bonding process for mechanical assembly and significantly reducing manufacturing complexity and time
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 enhances mechanical strength, compactness, and efficiency by reducing manufacturing time while ensuring high pressure resistance and uniform air temperature distribution.
Implementation Method 1
position a heat exchanger inside the distributor to facilitate heat exchange between the air flowing through the distributor towards the engine and one or more fluids flowing through the heat exchanger
Implementation Method 2
the plates of the stack of plates are fixed to each other by gluing and each end plate is fixed to one of the two half-shells by gluing
Implementation Method 3
the two half-shells are fixed to each other by welding
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
This air distributor (1) comprises two half-shells (2) made of plastic material and a stack of plates (4) made of plastic material, the two half-shells (2) defining a volume inside of which the stack of plates (4) is positioned, the stack of plates (4) comprising two end plates (40) and the stack of plates (4) defining between its adjacent plates (4) a set of intermediate spaces (10) suitable for a fluid circulation. The plates (4) of the stack of plates (4) are attached to one another, each end plate (40) is attached to one of the two half-shells (2), and the two half-shells (2) are attached to one another.