Resilient Blade Insert for Heat Exchanger Air Leakage

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Solution Overview

Problem

Existing heat exchangers in vehicle air conditioning systems face challenges in efficiently conditioning air for both the front and rear compartments at different temperatures without air leakage between compartments.

Innovation Solution

The use of a comb-shaped insert with resiliently deformable blades is introduced between the tubes of the heat exchanger, which are designed to be inserted between sections of the heat exchanger core to partition and condition air separately for each compartment, while maintaining mechanical strength and allowing minimal air crosstalk.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid partition structure is used to separate air flows, then air leakage between compartments is minimized, but the structure cannot adapt to thermal expansion and contraction of tubes

Engineering Contradiction:

Improveair leakage preventionVSAvoidadaptation to thermal expansion

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The partition structure uses resilient blades with spring portions that can dynamically deform and adapt to thermal expansion and contraction of the tubes. The spring portion allows the blade to move resiliently between tubes, maintaining the partition function while accommodating dimensional changes in the heat exchanger core.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The resilient blade is designed with a flexible spring portion that can elastically deform to accommodate thermal changes. This flexible element maintains the sealing and partition function while adapting to the dimensional changes of the rigid tube structure under thermal stress.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If multiple separate partition structures are used for each tube, then air flow separation is improved, but device complexity increases

Engineering Contradiction:

Improveair flow separationVSAvoidnumber of partition components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple resilient blades are integrally formed as a single comb-shaped insert structure with a common base. This merging of multiple partition elements into one integrated component reduces manufacturing complexity, assembly steps, and the number of separate parts while maintaining the air flow separation function across multiple tube locations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The comb-shaped insert with multiple blades serves multiple partitioning functions simultaneously across different tube locations. A single component performs the air separation function at multiple points in the heat exchanger core, reducing the overall number of components needed while achieving comprehensive air flow management.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If a comb-shaped insert is used to partition sections, then air flow separation is achieved, but manufacturing precision requirements increase due to the integral structure

Engineering Contradiction:

Improveair flow separationVSAvoiddimensional accuracy of blades

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The resilient blade incorporates a spring portion that changes its physical state between deformed and restored configurations. This parameter change allows the blade to accommodate dimensional variations and tolerances in the tube positions, reducing the stringency of manufacturing precision requirements for the insert while maintaining effective air flow separation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The spring portion of the resilient blade provides a cushioning effect that compensates for dimensional variations and misalignments between tubes. This built-in compliance mechanism absorbs the impact of manufacturing tolerances and assembly variations, reducing the overall precision requirements for the comb-shaped insert.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 configuration effectively separates air flows for the front and rear compartments, ensuring independent temperature conditioning while minimizing air leakage and allowing for easy detachment during maintenance.

Implementation Method 1

At least one of the blades has a spring portion, which is resiliently deformable and configured to be resiliently inserted between two of the tubes

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The spring portion is resiliently deformable inward to squish the aperture when the spring portion is inserted between two of the tubes

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9903670B2Insert for heat exchanger and heat exchanger having the same

Publication Date: 2018.02.27 DENSO INTERNATIONAL AMERICA INC

AI summary

An insert is configured to be inserted into a heat exchanger having a plurality of tubes. The insert includes a base and a multiple blades. The blades are extended from the base. At least one of the blades has a spring portion. The spring portion is resiliently deformable and configured to be resiliently inserted between two of the tubes.