Snap-Fit Sealing Element for Multi-Heat Exchanger Cooling Modules

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Solution Overview

Problem

Existing cooling modules with heat exchangers require multiple sealing elements and connecting means, leading to increased cost, complexity, and risk of damaging the heat exchanger core during assembly.

Innovation Solution

A symmetrical sealing element with a central part and flaps that snap-fit onto the heat exchangers, eliminating the need for external connecting means and allowing for efficient sealing between heat exchangers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple sealing elements and connecting means are used to seal gaps between heat exchangers, then sealing effectiveness is improved, but device complexity and cost increase

Engineering Contradiction:

Improvesealing effectivenessVSAvoidnumber of sealing components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple sealing elements and connecting means into a single integrated sealing element. The sealing element includes a body portion and multiple flaps that can seal multiple gaps between heat exchangers simultaneously, eliminating the need for separate sealing components and connecting means for each gap.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealing element is designed to perform multiple functions: it seals gaps between adjacent heat exchangers, provides structural support, and eliminates the need for separate connecting means. The flaps can engage with side plates of different heat exchangers, making the single sealing element universal for multiple sealing positions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple sealing elements and connecting means are used, then sealing effectiveness is improved, but assembly time increases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By merging multiple sealing and connecting functions into one component, the assembly process requires installing only one sealing element instead of multiple separate components, significantly reducing assembly time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealing element is pre-configured with multiple flaps and engagement features during manufacturing, so that during assembly, no additional connecting means or separate sealing components need to be attached - the sealing element is ready to perform all sealing functions immediately upon installation.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If connecting means are used to attach sealing elements, then sealing effectiveness is improved, but risk of heat exchanger damage increases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidrisk of heat exchanger core damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the connecting means from the sealing assembly, eliminating bolts or other rigid connectors that could damage heat exchanger cores during installation. The sealing element uses its own integrated flaps and engagement features that attach without requiring external connecting means.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The sealing element uses flexible flaps that can adapt to the heat exchanger geometry without applying excessive force. These flaps seal the gaps through their flexibility and elastic deformation rather than through rigid mechanical fastening, reducing the risk of damaging the heat exchanger core.

Inventive Principle:

Principle #30Flexible shells and thin films

4Reliability

If multiple sealing elements are used, then sealing effectiveness is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesealing effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple sealing elements into one integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation reduces manufacturing complexity and overall cost despite maintaining or improving sealing effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single sealing element is designed to be universal for multiple heat exchanger configurations and positions, replacing the need for multiple specialized sealing components. This universality reduces the variety of parts that need to be manufactured, lowering overall manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4112901B1Sealing element for heat exchangers in a cooling module

Publication Date: 2025.05.07 VALEO AUTOSYSTY

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AI summary

The present invention provides a cooling module for a vehicle. The cooling module include a first heat exchanger having at least one side plate, at least two second heat exchangers and a sealing element. The second heat exchangers are arranged on opposite sides of the first heat exchanger, and each heat exchanger includes at least one second side plate. Further, the sealing element includes a central part and at least two flaps attached to the opposite sides of the central part. Further, the central part is attached to the first heat exchanger and each flap is adapted to engage with the second side plate of the respective second heat exchanger.