Stacked Heat Exchanger Mounting via Elongate Members
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Solution Overview
Problem
In vehicle heat exchanger assemblies, the compact arrangement is hindered by space constraints under the bonnet, and existing solutions require multiple fasteners for each heat exchanger, complicating mounting and potentially limiting manufacturing tolerance and accommodating thermal expansion.
Innovation Solution
A heat exchanger assembly design featuring a first heat exchanger with tubes running in one direction and a second heat exchanger at an angle, using two side channels with elongate members and a connecting unit to reduce the number of fasteners required, allowing for a more compact arrangement and improved manufacturing tolerance, while accommodating thermal expansion through slots in the channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fasteners are used for each heat exchanger, then the mounting reliability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated side channel structure. The side channel incorporates multiple mounting positions and fastener locations that work together as one unified component, replacing what would traditionally require multiple separate fasteners and mounting operations for each heat exchanger.
Solution Approach 2:
The side channel structure serves multiple functions simultaneously: it provides structural support, incorporates mounting features for both heat exchangers, includes elongate members for thermal expansion accommodation, and integrates fastening mechanisms. This multi-functional design reduces the overall number of components needed.
2Volume of moving object
If a compact heat exchanger assembly is designed, then the space utilization is improved, but the manufacturing tolerance and thermal expansion accommodation become more difficult
Solution Approach 1:
The side channel incorporates elongate members that can move or adjust to accommodate thermal expansion of the heat exchangers. This dynamic feature allows the rigid side channel structure to flexibly adapt to dimensional changes in the heat exchangers during operation, maintaining proper fit and function despite temperature variations.
Solution Approach 2:
The elongate members are positioned within the side channel structure, with some features nested within others. The connecting unit fits within the side channel, and the elongate members are integrated into the side channel's mounting structure, creating a compact nested arrangement that maximizes space utilization.
3Device complexity
If the number of fasteners is reduced, then the device complexity is reduced, but the mounting strength may be compromised
Solution Approach 1:
The side channel structure merges multiple fastening functions into integrated features. Rather than using separate fasteners for each heat exchanger, the side channel incorporates elongate members and connecting units that perform multiple fastening and support functions simultaneously, maintaining strength while reducing component count.
Solution Approach 2:
The side channel appears to be constructed as a composite structure combining different materials or components (metal channels, elongate members, connecting units) that work together to provide both the necessary mechanical strength and the simplified fastening function. This composite approach allows strength to be distributed across the integrated structure rather than relying on multiple individual fasteners.
Data Source
AI summary
Two side channels are for mounting the first heat exchanger. Each side channel defines a back and two side walls protruding from the back. An elongate member is at each end of a tank of the first heat exchanger. Each elongate member extends through the tank and being attached at each end to one of the side walls of one of the two channels so that the elongate member spans the channel to mount the first heat exchanger to the channel. The tank includes a recessed region between two parts of the tank and the elongate member extends through an aperture defined in each of the parts, such that an exposed portion of the elongate member is outside the tank. The second heat exchanger is mounted to the exposed portions of two elongate members of the first heat exchanger via connecting unit.