Snap-Fit Heat Exchanger Bracket for Thermal Expansion Tolerance
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Solution Overview
Problem
Existing heat exchanger brackets in automotive cooling modules face durability issues due to thermal expansion and contraction, which can cause stress and require significant fastening hardware, increasing costs and reducing robustness.
Innovation Solution
A heat exchanger bracket designed with flexible plastic materials, featuring free floating retention points and flexible retainers that accommodate thermal expansion, reducing the need for extensive fastening hardware and enhancing durability while allowing for significant road load input tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metallic structures with good heat transfer characteristics are used, then heat transfer performance is improved, but thermal expansion and contraction cause significant stress on brackets and mounting points
Solution Approach 1:
The patent changes the material parameter from metal to plastic, which has different thermal expansion properties. The plastic bracket container absorbs thermal expansion stresses through its material characteristics, preventing stress concentration on mounting points while maintaining heat exchanger functionality throughout thermal cycles
Solution Approach 2:
The patent employs a composite material approach by integrating the bracket container and retainers as a single plastic component. This monolithic plastic structure combines mounting bracket and retaining functions, creating a composite assembly that handles both thermal expansion and mechanical retention without requiring separate metal fastening hardware
2Stability of the object's composition
If rigid fastening hardware is used to secure the heat exchanger, then structural stability is improved, but durability under thermal cycles is reduced
Solution Approach 1:
The patent transitions from rigid static fastening to a dynamic flexible retention system. The flexible retainers can deflect and move with thermal expansion, providing continuous retention force that adapts to changing dimensions. This dynamic retention maintains structural stability while accommodating thermal cycles without failure
Solution Approach 2:
The patent uses flexible retainers made of plastic material that can bend and deflect. These flexible components engage the heat exchanger and maintain retention through elastic deformation, allowing the retention system to absorb dimensional changes from thermal expansion while maintaining secure engagement
3Reliability
If extensive fastening hardware is used to accommodate thermal expansion, then tolerance for thermal cycles is improved, but cost and device complexity increase
Solution Approach 1:
The patent merges the bracket container and retainers into a single integrated plastic component. This consolidation eliminates the need for separate fastening hardware, as the retainers are built-in features of the bracket itself. The integrated design achieves thermal cycle tolerance through the plastic material properties and geometric design rather than through additional fastening elements
Solution Approach 2:
The patent replaces expensive metal fastening hardware with a cost-effective plastic bracket container and retainer assembly. The plastic components are molded as single pieces without requiring additional fasteners, reducing material costs, assembly complexity, and overall system cost while maintaining functional performance
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 solution provides a cost-effective, robust, and durable heat exchanger bracket that withstands thermal cycles and road loads without compromising performance, offering improved durability and reduced costs by minimizing fastening hardware and maintaining airflow efficiency.
Implementation Method 1
The first and second flexible retainers may be configured to engage opposing longitudinal ends of the heat exchanger responsive to insertion of the heat exchanger into the bracket container
Data Source
AI summary
A heat exchanger bracket for an automotive cooling module may include a first mounting assembly disposed at a first end of the heat exchanger bracket, a second mounting assembly disposed at a second end of the heat exchanger bracket, and a bracket container disposed between the first and second ends of the heat exchanger bracket. The first mounting assembly may include a first free floating retention point, and the second mounting assembly may include a second free floating retention point. The bracket container may be configured to receive a heat exchanger. The bracket container may include a first flexible retainer disposed at a first longitudinal end thereof, and a second flexible retainer disposed at a second longitudinal end thereof. The first and second flexible retainers may be configured to engage opposing longitudinal ends of the heat exchanger responsive to insertion of the heat exchanger into the bracket container.