Vehicle Air Conditioner Separator Elastic Assembly Seal
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Solution Overview
Problem
Conventional vehicle air conditioners face issues with air leaks and misassembly due to gaps between the evaporator and separator, leading to poor control of dual zone air volumes and increased manufacturing costs.
Innovation Solution
An air conditioner design featuring an assembly end portion with an insert-molded elastic material and a sealing part with an elastic sealing member and compression support part to securely fit the separator into the air inflow passageway, preventing air leaks and ensuring correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator is inserted into the air-conditioning case using a conventional rigid structure, then the assembly process is simple, but air leaks occur due to gaps between the evaporator and separator
Solution Approach 1:
The patent applies this principle by forming an elastic assembly end portion at the end of the separator that can elastically deform during insertion. This elastic portion creates a flexible sealing interface between the separator and the air-conditioning case, preventing air leaks while maintaining assembly simplicity. The elastic material allows the separator to conform to the mating surface, eliminating gaps without requiring complex sealing mechanisms.
Solution Approach 2:
The patent changes the physical parameter of the separator's end portion from rigid to elastic. By forming an elastic assembly end portion through insert molding, the separator's local flexibility is increased, enabling it to maintain intimate contact with the air-conditioning case surface. This parameter change transforms the separator from a purely rigid component to one with localized elastic properties that ensure sealing.
2Reliability
If the separator is made completely elastic to improve sealing, then air leaks are prevented, but assembly precision decreases due to deformation
Solution Approach 1:
The patent applies this principle by providing the separator with non-uniform properties: the main body remains rigid for structural stability and precise positioning, while only the assembly end portion is made elastic for sealing. This local differentiation allows the separator to maintain its overall shape and assembly precision while the elastic tip ensures intimate contact and sealing with the air-conditioning case surface.
Solution Approach 2:
The patent segments the separator into functionally distinct zones: a rigid main body for structural support and positioning, and an elastic assembly end portion for sealing. This segmentation allows each portion to perform its specific function optimally—the rigid body ensures assembly precision while the elastic end ensures sealability—without the drawbacks of making the entire separator either rigid or elastic.
3Productivity
If the separator is inserted quickly without guidance, then assembly speed increases, but misassembly occurs due to collision with the air-conditioning case
Solution Approach 1:
The patent applies this principle by providing guidance features (such as guide ribs or tapered edges) on the separator that engage with corresponding features in the air-conditioning case before the main insertion occurs. This preliminary guidance action aligns the separator correctly, preventing collision and misassembly, and enables the subsequent rapid insertion of the elastic assembly end portion without compromising assembly correctness.
4Reliability
If a tight fit is used between evaporator and separator to prevent air leaks, then sealing improves, but manufacturing cost increases
Solution Approach 1:
The patent applies this principle by designing the separator's elastic assembly end portion to self-seal against the air-conditioning case through its own elastic deformation. The elastic material naturally conforms to the mating surface and maintains sealing pressure without requiring additional sealing components, adhesives, or complex assembly operations. This self-sealing mechanism achieves reliable sealing while keeping manufacturing simple and cost-effective.
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
Enhances sealability between the heat exchanger and separator, improving control of dual zone air volumes, reducing air leaks, and simplifying assembly to lower manufacturing costs.
Implementation Method 1
a sealing part extending from one end of the separator in the longitudinal direction, and having a sealing surface that comes into contact with the heat exchanger
Implementation Method 2
an assembly end portion provided at one end of the separator in the longitudinal direction, and having an insertion portion inserted into the air inflow passageway
Data Source
AI summary
Disclosed herein is an air conditioner for a vehicle, which includes: an air-conditioning case (120) having an air passageway for connecting an air inflow port (127) and an air outflow port (128) with each other; an evaporator (130) and a heater core (140) mounted on the air passageway; a blower unit (110) disposed at the side of the air inflow port (127) to blow air to the inside of the air-conditioning case (120); and a separator (150) disposed at the upstream side of the evaporator (130) to divide air, which is introduced into an air inflow passageway (227) of the air-conditioning case (120), into the right and the left. The air conditioner further includes an assembly end portion (152) disposed at an end portion of one side of the separator (150) to be inserted and assembled on the air inflow passageway (227) of the air-conditioning case (120) by forced fitting.