Radiator U-Shaped End Plate Design for Sealing and Weight Reduction
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Solution Overview
Problem
Conventional radiators used in motor vehicles are complex, heavy, and expensive due to their numerous components, and they face challenges in achieving perfect sealing between the radiator and the HVAC system chamber, which complicates installation and increases costs.
Innovation Solution
A radiator design featuring a U-shaped end plate oriented towards the outside, eliminating the need for spacers and simplifying the architecture by directly contacting the tubes, thereby reducing the number of components and improving sealing efficiency without compromising heat exchange performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional radiators use multiple components including spacers and complex end structures, then the structural integrity and heat exchange function are maintained, but the device complexity increases, weight increases, and manufacturing cost increases
Solution Approach 1:
The patent merges the end plate and tube support functions into a single integrated U-shaped end plate structure. The end plate simultaneously serves as the terminal boundary of the radiator core and as the support structure for mounting tubes, eliminating the need for separate spacer components and complex end assemblies. This consolidation reduces the number of parts while maintaining structural integrity.
Solution Approach 2:
The U-shaped end plate performs multiple functions: it closes the radiator core at the end, provides mounting surfaces for tubes, supports the evaporator assembly, and serves as a structural reinforcement element. This multi-functionality replaces multiple specialized components with a single versatile structure, reducing overall device complexity.
2Stability of the object's composition
If conventional radiators use spacers and complex end structures, then the structural stability is maintained, but the manufacturing cost and weight increase
Solution Approach 1:
By combining the end plate and support structures into a single U-shaped component, the patent eliminates redundant materials and reduces overall weight. The integrated design removes the need for separate spacer components and complex end assemblies, achieving weight reduction while maintaining structural stability through the unified geometry of the end plate.
3Reliability
If conventional radiators use complex end structures with multiple components, then the heat exchange function is maintained, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent integrates the end plate and tube support functions into a single component that can be manufactured as one piece or pre-assembled unit. This reduces the number of manufacturing steps, eliminates the need for multiple assembly operations, and simplifies quality control, thereby improving ease of manufacture while maintaining heat exchange functionality.
Solution Approach 2:
The U-shaped end plate is designed as a modular component that can be separately manufactured and then assembled to the radiator core. This segmentation allows for specialized manufacturing processes to be applied to the end plate independently, simplifying production and reducing overall manufacturing complexity.
4Reliability
If conventional radiators use traditional sealing methods with end seals and covers, then the sealing function is achieved, but the device complexity and installation time increase
Solution Approach 1:
The patent integrates the sealing function directly into the U-shaped end plate structure. The end plate itself provides the sealing interface with the evaporator assembly, eliminating the need for separate end seals, gaskets, and closing covers. This integration simplifies the sealing structure while maintaining effective sealing.
5Reliability
If conventional radiators use multiple assembly steps including seal installation and cover securing, then the sealing function is achieved, but the installation time increases
Solution Approach 1:
By integrating the sealing function into the U-shaped end plate structure, the patent eliminates multiple assembly steps. The end plate is installed as a single component that simultaneously provides structural closure and sealing, removing the need for separate seal installation, cover attachment, and fastening operations, thereby significantly reducing installation 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
This design reduces the weight and cost of the radiator while enhancing the sealing function between the radiator and the HVAC system chamber, simplifying manufacturing and installation processes.
Implementation Method 1
said bottom extending at least in part into contact with the first tube (1201) located at the first end (1) of the body (12)
Implementation Method 2
a body (12) comprising a plurality of tubes (120)... to cool or heat fluids
Implementation Method 3
optimize the airflow through the body (12)
Data Source
Figure 1~2
Figure 3~4
Figure 5~9
AI summary
The invention relates to a radiator (1) comprising a body (12) and two containers (10, 11) disposed on two opposing sides of the body (12), said body (12) comprising a plurality of pipes (120) opening at each end into one of the containers (10, 11), said body (12) comprising an end plate (123) disposed at a first end and extending substantially between the containers (10, 11). According to the invention, the end plate (123) has an essentially U-shaped cross-section with a base (1231) extending into two side wings (1232), said base (1231) extending at least partially in contact with the first (120) of the pipes (120), located at the above-mentioned first end of the body (12), each pipe (120) being disposed between two spacers (121) except the first pipe (1201), with no spacer (121) being disposed between the base (1231) of the end plate (123) and the first pipe (1201), said wings (1232) extending from the base (1231) outwards from the body (12).