Lightweight plastic thermostat assembly

Abstract

The utility model is applicable to the technical field of automobile engine thermostat structures, and particularly relates to a lightweight plastic thermostat assembly, which comprises a thermostat cover and a cylinder cover interface shell, a wax thermolator and a small circulation channel are mounted in the cylinder cover interface shell, the thermostat cover and the cylinder cover interface shell are both made of plastic materials, and the thermostat cover and the cylinder cover interface shell are made of plastic materials. The cylinder cover connector shell comprises a thermolator fixing section and a cooling liquid guiding section which are integrally formed through injection molding, and the thermostat cover is detachably connected to the thermolator fixing section. The thermostat cover and the cylinder cover connector shell are made of the plastic materials, the thermolator fixing section and the cooling liquid guiding section are designed to be of the injection molding integrated structure, the overall weight is effectively reduced, the weight is reduced by about 40% compared with a traditional metal structure, and the requirement for light weight of an engine is met.

Description

Technical Field

[0001] This utility model relates to the technical field of automotive engine thermostat structure, specifically a lightweight plastic thermostat assembly. Background Technology

[0002] As the automotive industry increasingly demands energy conservation, emission reduction, and lightweighting, traditional diesel engine thermostats made of aluminum alloy are gradually revealing problems such as complex processing, heavy weight, and low surface roughness. After casting, the aluminum alloy structure still requires secondary precision machining to ensure the accuracy of the mounting holes and surfaces. Furthermore, its internal cavity has irregularities that can increase coolant flow resistance, hindering cooling efficiency. In addition, the high weight of aluminum components is detrimental to achieving overall vehicle weight reduction goals and increases manufacturing costs and assembly burden.

[0003] In existing technologies, some thermostat assemblies have attempted to incorporate plastic materials, but these are mostly multi-part combinations, resulting in complex assembly, difficulties in ensuring connection strength and sealing, and inconvenience during the disassembly and maintenance of wax-based thermostats. Therefore, there is an urgent need for a thermostat assembly structure that is structurally sound, lighter, easier to manufacture, and convenient for later maintenance, in order to further improve the overall performance and manufacturing economy of the engine cooling system. Utility Model Content

[0004] The purpose of this utility model embodiment is to provide a lightweight plastic thermostat assembly, which aims to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A lightweight plastic thermostat assembly includes a thermostat cover and a cylinder head interface housing. The cylinder head interface housing has a wax thermostat and a small circulation channel installed inside. Both the thermostat cover and the cylinder head interface housing are made of plastic. The cylinder head interface housing includes an injection-molded thermostat fixing section and a coolant guiding section. The thermostat cover is detachably connected to the thermostat fixing section.

[0007] Furthermore, the surface of the thermostat cover is provided with a third mounting flange, and the surface of the third mounting flange is provided with several fixing holes. The surface of the thermostat fixing section is provided with a second mounting flange, and the surface of the second mounting flange is provided with several fixing threaded sleeves. The internal meshing connection of the fixing threaded sleeves is a locking bolt, and the surface of the locking bolt is fitted with a bolt pressure ring.

[0008] Furthermore, the inner diameter of the fixing hole is the same as the outer diameter of the fixing sleeve, and the outer diameter of the locking bolt is the same as the inner diameter of the fixing sleeve.

[0009] Furthermore, the end face of the coolant guide section is provided with a first mounting flange, and the surface of the first mounting flange is provided with a first mounting groove, and a first sealing ring is installed inside the first mounting groove.

[0010] Furthermore, the surface of the second mounting flange is provided with a second mounting groove, and a second sealing ring is provided inside the second mounting groove.

[0011] Furthermore, the surface of the thermostat fixing section is provided with a second reinforcing rib.

[0012] Furthermore, the coolant guide section is provided with a first reinforcing rib.

[0013] Furthermore, the surface of the thermostat fixing section is provided with a fourth mounting flange, which is used to install the warm air inlet pipe.

[0014] Furthermore, the surface of the first mounting flange is provided with a plurality of mounting bushings.

[0015] The lightweight plastic thermostat assembly provided by this utility model has the following beneficial effects:

[0016] This invention effectively reduces overall weight by using plastic for the thermostat cover and cylinder head interface housing, and by designing the thermostat fixing section and coolant guide section as a single injection-molded structure. This results in approximately 40% weight reduction compared to traditional metal structures, meeting the requirements for lightweight engines. The thermostat cover and thermostat fixing section are detachably connected, facilitating future maintenance and replacement of the wax-based thermostat and improving maintenance efficiency. This structure boasts high overall precision, excellent sealing performance, and requires no further processing, offering advantages such as low manufacturing cost and convenient assembly, making it suitable for engine cooling systems. Attached Figure Description

[0017] Figure 1 This is a front structural diagram of a lightweight plastic thermostat assembly.

[0018] Figure 2 This is a schematic diagram of the back structure of a lightweight plastic thermostat assembly.

[0019] Figure 3 This is a schematic diagram of a lightweight plastic thermostat assembly in which the thermostat cover and cylinder head interface housing are separated.

[0020] In the diagram: 1. Thermostat cover; 2. Thermostat fixing section; 3. Coolant guide section; 4. First sealing ring; 5. First mounting groove; 6. Small circulation channel; 7. Mounting bushing; 8. First reinforcing rib; 9. Wax thermostat; 10. First mounting flange; 11. Second mounting flange; 12. Third mounting flange; 13. Second reinforcing rib; 14. Fourth mounting flange; 15. Bolt pressure ring; 16. Locking bolt; 17. Fixing hole; 18. Fixing threaded sleeve; 19. Second sealing ring. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0022] The specific implementation of this utility model will be described in detail below with reference to specific embodiments.

[0023] like Figures 1-3 As shown in the figure, a lightweight plastic thermostat assembly provided by this utility model includes a thermostat cover 1 and a cylinder head interface housing. The cylinder head interface housing is equipped with a wax thermostat 9 and a small circulation channel 6. Both the thermostat cover 1 and the cylinder head interface housing are made of plastic. The cylinder head interface housing includes a thermostat fixing section 2 and a coolant guiding section 3 that are integrally molded by injection. The thermostat cover 1 is detachably connected to the thermostat fixing section 2.

[0024] The surface of the thermostat cover 1 is provided with a third mounting flange 12, and the surface of the third mounting flange 12 has several fixing holes 17. The surface of the thermostat fixing section 2 is provided with a second mounting flange 11, and the surface of the second mounting flange 11 is provided with several fixing threaded sleeves 18. The fixing threaded sleeves 18 are internally engaged with locking bolts 16, and the surface of the locking bolts 16 is fitted with bolt pressure rings 15. The inner diameter of the fixing holes 17 is the same as the outer diameter of the fixing threaded sleeves 18, and the outer diameter of the locking bolts 16 is the same as the inner diameter of the fixing threaded sleeves 18.

[0025] This utility model provides a lightweight plastic thermostat assembly, including a thermostat cover 1 and a cylinder head interface housing. The cylinder head interface housing is integrally molded from a thermostat fixing section 2 and a coolant guiding section 3. A wax thermostat 9 is installed inside the thermostat fixing section 2 and communicates with a small circulation channel 6 to achieve localized cooling circulation during engine start-up. The thermostat cover 1 is a detachable structure and is reliably assembled with the thermostat fixing section 2 through multiple connecting structures, thereby forming a sealed coolant circulation chamber.

[0026] Regarding the connection structure, the surface of the thermostat cover 1 is provided with a third mounting flange 12, and the third mounting flange 12 is provided with multiple fixing holes 17; the upper part of the thermostat fixing section 2 is provided with a second mounting flange 11, and the second mounting flange 11 is provided with multiple fixing sleeves 18. The specific connection process is as follows: align the thermostat cover 1 with the thermostat fixing section 2, so that the fixing holes 17 and the fixing sleeves 18 are coaxial; pass the locking bolts 16 through the fixing holes 17 in sequence and screw them into the internal threads of the fixing sleeves 18. During the locking process, the bolt pressure ring 15 sleeved on the outside of the locking bolts 16 presses against the flange surface between the thermostat cover 1 and the thermostat fixing section 2, thereby achieving reliable sealing and anti-loosening function.

[0027] The thermostat cover 1 is connected to the second mounting flange 11 of the thermostat fixing section 2 via the third mounting flange 12, thereby pressing and sealing the wax thermostat 9. The wax thermostat 9 is installed in the limiting cavity inside the thermostat fixing section 2, and its bottom is positioned with the seat hole via the sealing element 19. The elastic structure at its upper end abuts against the inner surface of the thermostat cover 1, forming a stable support.

[0028] A small circulation channel 6 is formed on one side of the coolant guide section 3, and it is connected to the main circulation channel controlled by the wax thermostat 9 through a transition channel. During cold start, the coolant enters the internal flow chamber through the small circulation channel 6, flows through the guide section 3 to the engine block, and achieves small circulation cooling. When the coolant temperature rises, the wax thermostat 9 opens the main circulation channel, and the coolant can flow to the radiator through the outlet 1 of the thermostat cover 1, achieving the large circulation cooling function.

[0029] This structure utilizes plastic injection molding. The separate design of the thermostat cover 1 and the cylinder head interface housing not only facilitates the later replacement and maintenance of the wax thermostat 9, but also effectively avoids the weight and processing cost burden of traditional aluminum alloy materials. The overall weight is reduced by approximately 40% compared to aluminum alloy structures, and secondary finishing is eliminated. The structural design, combined with the bolt pressure ring 15 and fixing sleeve 18, enhances the uniformity of stress at the connection points, improves the sealing effect and overall strength, and is suitable for cooling systems of various lightweight passenger or commercial vehicle engines.

[0030] In summary, this utility model, through its modular plastic structure design, solves the problems of large thermostat weight, high manufacturing cost, and complex disassembly and assembly in the prior art, and has good engineering adaptability and market promotion value.

[0031] In this embodiment, a first mounting flange 10 is provided on the end face of the coolant guide section 3, and a first mounting groove 5 is formed on the surface of the first mounting flange 10. A first sealing ring 4 is installed inside the first mounting groove 5. The first mounting flange 10 is located on the end face of the coolant guide section 3 and is used to interface and connect the thermostat assembly to the engine cylinder head or other cooling system components. By setting the flange structure, a stable connection surface can be provided, and axial sealing can be easily achieved. The first mounting groove 5 is formed on the surface of the first mounting flange 10, which is used to define the installation position of the seal and ensure that the sealing ring will not be displaced or squeezed out during the connection process.

[0032] The first sealing ring 4 is installed inside the first mounting groove 5, serving as a coolant seal to prevent leakage during circulation. This sealing structure design provides good compressive preload when the locking bolts are tightened, ensuring a reliable press-fit between the sealing rings and the interface surfaces. This improves the sealing reliability and service life of the entire thermostat assembly, adapting to the coolant operating conditions required by the engine under high temperature and high pressure.

[0033] In this embodiment, a second mounting groove is formed on the surface of the second mounting flange 11, and a second sealing ring 19 is disposed inside the second mounting groove. The second mounting flange 11 is located on the upper surface of the thermostat fixing section 2 and is used to achieve a reliable connection with the thermostat cover 1. In order to ensure the sealing effect of the connection area, a second mounting groove is formed on the surface of the second mounting flange 11, which is used to precisely define the installation position of the second sealing ring 19.

[0034] The second sealing ring 19 is disposed inside the second mounting groove. After the thermostat cover 1 and the thermostat fixing section 2 are assembled using locking bolts 16, the second sealing ring 19 is pressed between the two flange faces, thereby forming a sealing interface and effectively preventing coolant leakage from the inside of the thermostat to the outside. This sealing structure can maintain stable sealing performance under thermal expansion and contraction and long-term vibration environments, improving the reliability and durability of the thermostat assembly and meeting the sealing requirements during engine operation.

[0035] In this embodiment, a second reinforcing rib 13 is provided on the surface of the thermostat fixing section 2. A first reinforcing rib 8 is provided inside the coolant guiding section 3. The second reinforcing rib 13 is provided on the outer surface of the thermostat fixing section 2, and its shape is arranged in an arc along the flange contour direction, forming a reinforced connection between multiple bolt fixing areas. This structure effectively improves the deformation resistance of the assembly area between the thermostat cover 1 and the thermostat fixing section 2 without increasing the overall material usage, making it less prone to local indentation or stress concentration when the structure is subjected to the axial preload of the locking bolt 16, thereby enhancing the overall connection stability and sealing reliability.

[0036] The first reinforcing rib 8 is located inside the coolant guide section 3. It is a rib-like structure extending longitudinally along the flow path and is directionally reinforced based on the inner cavity contour of the guide section 3. This reinforcing rib not only enhances the structural strength of the inner cavity but also acts as a flow guide and separator, ensuring stable flow lines for the coolant as it flows through the guide channel, reducing turbulence and local flow resistance. This design effectively improves coolant flow rate control and guiding performance, while also enhancing the plastic shell's resistance to deformation under thermal expansion and contraction and vibration conditions, thus extending the structural service life.

[0037] In this embodiment, a fourth mounting flange 14 is provided on the surface of the thermostat mounting section 2, and the fourth mounting flange 14 is used to install the heater inlet pipe. Through this interface, engine coolant can be guided to the vehicle's heating system. This structure realizes the function of guiding coolant during the heating of the passenger compartment air, improving passenger compartment comfort, and is an important connection point between the engine cooling system and the heating system.

[0038] In this embodiment, the surface of the first mounting flange 10 is provided with a plurality of mounting bushings 7. These bushings are used to install connecting bolts. The bushing structure enhances the compressive strength at the bolt fixing point, preventing deformation or damage to the plastic flange due to excessive tightening force. At the same time, the mounting bushings 7 improve the coaxiality and stability of the connection, ensuring reliable fastening and sealing between the thermostat assembly and the engine cylinder head.

[0039] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A lightweight plastic thermostat assembly comprising a thermostat cover (1) and a cylinder head interface housing, and a wax regulator (9) and a small circulation channel (6) are installed inside the cylinder head interface housing, characterized in that, The thermostat cover (1) and the cylinder cover interface shell are both made of plastic material, the cylinder cover interface shell comprises a thermostat fixing section (2) and a cooling liquid guiding section (3) which are integrally formed by injection molding, and the thermostat cover (1) is detachably connected to the thermostat fixing section (2).

2. A lightweight plastic thermostat assembly according to claim 1, wherein, The surface of the thermostat cover (1) is provided with a third mounting flange (12), a plurality of fixing holes (17) are formed in the surface of the third mounting flange (12), the surface of the thermostat fixing section (2) is provided with a second mounting flange (11), a plurality of fixed screw sleeves (18) are arranged on the surface of the second mounting flange (11), the inside of the fixed screw sleeve (18) is engagedly connected with a locking bolt (16), and the surface of the locking bolt (16) is sleeved with a bolt pressing ring (15).

3. A lightweight plastic thermostat assembly according to claim 2, wherein, The inner diameter of the fixing hole (17) is the same as the outer diameter of the fixed screw sleeve (18), and the outer diameter of the locking bolt (16) is the same as the inner diameter of the fixed screw sleeve (18).

4. The lightweight plastic thermostat assembly of claim 1, wherein, The end surface of the cooling liquid guiding section (3) is provided with a first mounting flange (10), a first mounting groove (5) is formed in the surface of the first mounting flange (10), and a first sealing ring (4) is arranged in the inside of the first mounting groove (5).

5. The lightweight plastic thermostat assembly of claim 2, wherein, The surface of the second mounting flange (11) is provided with a second mounting groove, and the second mounting groove is provided with a second sealing ring (19).

6. The lightweight plastic thermostat assembly of claim 1, wherein, The inside of the cooling liquid guiding section (3) is provided with a first reinforcing rib (8).

7. The lightweight plastic thermostat assembly of claim 1, wherein, The surface of the thermostat fixing section (2) is provided with a second reinforcing rib (13).

8. The lightweight plastic thermostat assembly of claim 1, wherein, The surface of the thermostat fixing section (2) is provided with a fourth mounting flange (14), and the fourth mounting flange (14) is used for mounting a warm air inlet pipe.

9. The lightweight plastic thermostat assembly of claim 4, wherein, The surface of the first mounting flange (10) is provided with a plurality of mounting bushings (7).

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