Snap-Fit Hermetic Cap for Heat Exchanger Modulators
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Solution Overview
Problem
The existing cap assembly for a modulator in automotive heat exchangers is costly due to complex design, requires multiple assembly steps, and is difficult to disassemble, relying on multiple machining processes and O-rings for sealing.
Innovation Solution
A single-piece cap with snap-fit engagement and O-ring grooves for hermetic sealing, featuring tapered protrusions and flexible legs for secure attachment and easy removal, eliminating the need for separate male and female caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional multi-component cap assembly with O-rings and multiple machining processes is used, then hermetic sealing is achieved, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate components (caps, O-rings, sealing elements) into a single integrated cap component. The cap includes integrated sealing surfaces, protrusions for engagement, and recesses for O-ring placement, eliminating the need for separate assembly steps and reducing overall complexity while maintaining hermetic sealing functionality.
Solution Approach 2:
The single cap component performs multiple functions simultaneously: it provides hermetic sealing through integrated sealing surfaces and O-ring recesses, structural support through its rigid construction, and mechanical engagement through protrusions that interface with the modulator. This multi-functionality reduces the number of parts needed while achieving all required performance objectives.
2Reliability
If a traditional multi-component cap assembly with multiple machining processes is used, then hermetic sealing is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple separate components (caps, O-rings, sealing elements) into a single integrated cap component. The cap includes integrated sealing surfaces, protrusions for engagement, and recesses for O-ring placement, eliminating the need for separate assembly steps and reducing overall complexity while maintaining hermetic sealing functionality.
3Reliability
If a traditional multi-component cap assembly is used, then hermetic sealing is achieved, but disassembly difficulty increases
Solution Approach 1:
The cap incorporates flexible legs with protrusions that can dynamically change their engagement state. During normal operation, the protrusions are engaged with the modulator for secure attachment. During disassembly, the flexible legs can be manually manipulated to disengage the protrusions, enabling easy removal without special tools while maintaining reliable sealing during operation.
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 single-piece cap reduces manufacturing and assembly costs, simplifies the assembly process, and provides a reliable hermetic seal with improved ease of disassembly without requiring additional tools.
Implementation Method 1
an upper portion defining a pair of grooves extending annularly about and axis and configured to receive O-rings for hermetically sealing against an inner wall of a modulator
Implementation Method 2
a pair of tapered protrusions, each protrusion extending radially outward from a respective one of the legs, each protrusion having a tapered surface extending oblique to the axis and a transverse surface extending transverse to the axis when the cap is assembled to the modulator. The protrusions are configured to fit through corresponding openings in the modulator to attach the cap to the modulator.
Implementation Method 3
The single-piece cap also includes a lower portion having a frame and a pair of legs extending downward from the upper portion, the legs being flexible relative to the frame.
Data Source
AI summary
A receiver drier assembly for an automotive heat exchanger is provided with a single-piece cap. In embodiments described herein, a modulator has a tubular wall and one or more openings are formed therein. The cap is a single-piece cap and is configured to attach directly to the tubular wall via a snap fit. The cap may have a protrusion that is configured to snap into engagement with the opening in the modulator when properly assembled. The protrusion may be tapered such that as the cap is assembled to the modulator, the protrusion is forced radially inwardly via the tapered surface sliding along the tubular wall. Once the protrusion meets the opening, the protrusion is allowed to flex radially outward toward its natural unbiased position, snap fitting with the opening of the tubular wall.