An integrated thermostat cap

Abstract

The utility model discloses an integrated temperature regulator cover belongs to temperature regulator technical field. The temperature regulator cover includes metal base, and the innovation is in the cooling liquid contact surface of metal base and is covered with composite coating, and the coating is composed of inorganic conversion bottom layer that combines with the base and organic polymer sealing surface layer that covers on it, and the corrosion problem of metal base is solved in cooperation. Meanwhile, the integral type sealing ring is inserted in the annular sealing groove of cover body connecting end face with interference, and the cross section of the sealing ring is double lip edge structure, including annular mounting portion and the first, second annular lip edge that extend outward. The utility model discloses through "composite coating " and " integral type double -lipped sealing ring " structure, has promoted the corrosion resistance and the reliability of end face sealing of product, has effectively prolonged the service life.

Description

Technical Field

[0001] This utility model relates to the field of thermostat technology, specifically to an integrated thermostat cover. Background Technology

[0002] As a key component of the engine cooling system, the thermostat's core function is to automatically adjust the coolant circulation path based on the coolant temperature, thereby ensuring that the engine always operates within its optimal temperature range. The integrated thermostat cover, serving as the connection between the thermostat assembly and the engine or other cooling system components (such as the water pump and radiator), not only needs to support and secure the thermostat, but its internal components also directly form the coolant flow channels. Therefore, its performance and reliability are crucial to the stable operation of the entire cooling system.

[0003] Currently, most integrated thermostat covers on the market are manufactured from aluminum alloy using die-casting to meet the requirements of lightweight design, structural strength, and complex shape forming. However, aluminum alloy materials face severe corrosion challenges under long-term contact with engine coolant (which typically contains ethylene glycol, water, and various chemical additives such as corrosion inhibitors and buffers), including uniform corrosion, pitting corrosion, and cavitation caused by coolant flow or cavitation. This corrosion gradually weakens the structural integrity of the cover, potentially leading to coolant leakage or even system failure.

[0004] To improve corrosion resistance, existing technologies often treat the surface of aluminum alloy thermostat covers. One common practice is to perform inorganic conversion treatments such as anodizing to form an oxide film. While this method improves the corrosion resistance of the substrate to some extent, the resulting film usually contains micropores and lacks density. When in prolonged contact with coolants with complex chemical compositions, its protective effect is limited. Furthermore, the film itself is relatively brittle and prone to microcracks under thermal or mechanical stress, becoming the initiation point for corrosion.

[0005] On the other hand, in terms of sealing design, traditional thermostat covers and mating components typically use independent O-rings or flat gaskets for end-face sealing. This sealing method requires high precision in the machining of the mounting groove and high flatness of the end face. In actual use, engine vibration, component deformation caused by thermal cycling, and aging of the sealing material can easily lead to stress relaxation at the sealing interface, resulting in poor sealing and coolant leakage. Furthermore, a single sealing lip structure is relatively weak in compensating for minor unevenness of the end face, and its reliability needs further improvement.

[0006] Therefore, we propose an integrated thermostat cover. Utility Model Content

[0007] (a) Technical problems to be solved To address the shortcomings of existing technologies, this utility model provides an integrated thermostat cover. Through a "composite coating" and an "integrated double-lip sealing ring" structure, the corrosion resistance and sealing reliability of the thermostat cover are synergistically improved, thereby extending its service life and effectively solving the problems in the background technology.

[0008] (II) Technical Solution To achieve the above objectives, the technical solution adopted by this utility model is as follows: an integrated thermostat cover, comprising a cover body made of a metal substrate, wherein the surface of the metal substrate in contact with the coolant is covered with a composite coating, the composite coating being composed of a bottom layer and a top layer with different functions; the bottom layer is an inorganic conversion layer bonded to the metal substrate, and the top layer is an organic polymer sealing layer covering the bottom layer; an annular sealing groove is provided on the connecting end face of the cover body, and an integrated sealing ring is interference-fitted into the annular sealing groove; the cross-section of the integrated sealing ring is a double-lip structure, the integrated sealing ring including an annular mounting part for fixing with the annular sealing groove, and a first annular lip and a second annular lip extending outward from the annular mounting part.

[0009] Preferably, the material of the integrated sealing ring is fluororubber or EPDM rubber.

[0010] Preferably, the metal matrix is ​​an aluminum alloy die-casting.

[0011] Preferably, the inorganic conversion layer is an anodic oxide layer, a micro-arc oxide layer, or a ceramic conversion film layer.

[0012] Preferably, the organic polymer sealing layer is an epoxy resin layer, a fluorocarbon coating, or a polyurethane coating.

[0013] Preferably, the composite coating also covers the outer surface of the metal substrate.

[0014] Preferably, hard ceramic microparticles are dispersed within the surface layer.

[0015] Preferably, the hard ceramic particles are alumina, silicon dioxide, or silicon carbide particles.

[0016] Preferably, the Shore A hardness of the integrated sealing ring is 70 to 85 degrees.

[0017] Preferably, the total thickness of the composite coating is 20 μm to 50 μm; wherein the thickness of the bottom layer is 5 μm to 20 μm, and the thickness of the top layer is 10 μm to 30 μm.

[0018] (III) Beneficial Effects Compared with the prior art, this utility model provides an integrated thermostat cover, which has the following advantages: 1. This integrated thermostat cover achieves dual protection by applying a composite coating consisting of an inorganic conversion underlayer and an organic polymer sealing layer on the surface of the metal substrate in contact with the coolant. The inorganic conversion underlayer has strong adhesion to the metal substrate, providing excellent substrate adhesion and basic corrosion resistance. The organic polymer sealing layer forms a dense, smooth, and inert chemical barrier, effectively isolating the coolant and its additives from direct corrosion and cavitation of the metal substrate. This composite coating structure fundamentally solves the long-term corrosion problem of aluminum alloy parts in the cooling system and extends the service life of the thermostat cover.

[0019] 2. This integrated thermostat cover innovatively adopts an interference fit integrated double-lip sealing ring on the connection end face; the double-lip structure can generate two independent sealing lines when under pressure, and can maintain a stable and durable sealing effect even under slight unevenness on the end face or long-term vibration conditions, with stronger compensation ability and reduced leakage probability of the main sealing interface. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an integrated thermostat cover according to the present invention.

[0021] Figure 2 This is a partial structural schematic diagram of an integrated thermostat cover according to the present invention.

[0022] Figure 3 This is a side cross-sectional view of the integrated sealing ring in the integrated thermostat cover of this utility model.

[0023] Figure 4 This is a schematic diagram of the layered structure of the composite coating in an integrated thermostat cover according to this utility model.

[0024] In the figure: 1. Metal substrate; 2. Composite coating; 3. Integrated sealing ring; 4. Annular sealing groove; 5. Annular mounting part; 6. First annular lip; 7. Second annular lip; 8. Bottom layer; 9. Top layer. Detailed Implementation

[0025] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0026] like Figure 1-4 As shown, this utility model provides an integrated thermostat cover, including a cover body made of a metal substrate 1. The metal substrate 1 is preferably an aluminum alloy die-casting part to meet the requirements of lightweight design and complex structural forming.

[0027] The inner surface of the metal substrate 1 that comes into contact with the coolant is covered with a composite coating 2. For example... Figure 4As shown, the composite coating 2 consists of a base layer 8 and a top layer 9 with different functions. The base layer 8 is an inorganic conversion layer bonded to the metal substrate 1, and its specific type can be an anodic oxide layer, a micro-arc oxidation layer, or a ceramic conversion film layer. This base layer 8 is formed through chemical conversion, has strong adhesion to the metal substrate 1, and provides excellent substrate adhesion and basic corrosion protection. The top layer 9 is an organic polymer sealing layer covering the base layer 8, and its specific type can be an epoxy resin layer, a fluorocarbon coating, or a polyurethane coating. This top layer 9 forms a dense, smooth, and inert chemical barrier, which can effectively isolate the coolant and its additives from direct corrosion and cavitation of the metal substrate. As a preferred embodiment, the total thickness of the composite coating 2 is controlled between 20 μm and 50 μm; the thickness of the base layer 8 is 5 μm to 20 μm, and the thickness of the top layer 9 is 10 μm to 30 μm. This thickness range can ensure protective performance while avoiding the risk of affecting dimensional accuracy or cracking due to excessive coating thickness. In another preferred embodiment, hard ceramic particles, such as alumina, silicon dioxide, or silicon carbide particles, may be dispersed within the surface layer 9. The addition of these hard particles can improve the wear resistance and cavitation resistance of the surface layer 9.

[0028] To further enhance the protective effect, the composite coating 2 can also selectively cover the outer surface of the metal substrate 1, achieving all-round protection for the metal substrate 1.

[0029] An annular sealing groove 4 is provided on the connecting end face of the cover. An integral sealing ring 3 is interference-fitted into the annular sealing groove 4. Figure 3 As shown, the integrated sealing ring 3 has a double-lip structure in cross-section, including an annular mounting portion 5 for fixing to the annular sealing groove 4, and a first annular lip 6 and a second annular lip 7 extending outward from the annular mounting portion 5. This double-lip structure can generate two independent sealing lines under pressure. Even under conditions of slight unevenness at the end face, thermal expansion and contraction of components, or long-term vibration, it can still maintain a stable and durable sealing effect through the elastic deformation of the lips. Its compensation capability and sealing reliability are far superior to single-lip or traditional O-ring structures.

[0030] The integral sealing ring 3 is preferably made of fluororubber (FKM) or ethylene propylene diene monomer (EPDM). Fluororubber has excellent resistance to high temperatures and chemical corrosion from coolants, while EPDM offers good resistance to water vapor, aging, and cost advantages. The choice can be made based on specific engine operating conditions and cost requirements. The Shore A hardness of the integral sealing ring 3 is preferably between 70 and 85. This hardness range ensures that the sealing ring has sufficient rigidity to maintain its stable fixation within the sealing groove, while also possessing the necessary elasticity to allow the double lips to deform effectively and generate sufficient sealing contact pressure.

[0031] The working principle of this utility model is as follows: When the thermostat cover is installed on the engine or other cooling system components, the connecting end faces are tightened by bolts. The integrated sealing ring 3 is subjected to axial compression, and its first annular lip 6 and second annular lip 7 undergo elastic deformation, tightly fitting the end faces of the mating components to form two reliable sealing barriers. As the coolant flows through the internal channels of the cover, it is effectively isolated by the composite coating 2. The bottom layer 8 provides strong adhesion and basic protection, while the top layer 9 provides a dense, chemically inert primary protective layer, together resisting coolant corrosion and cavitation damage.

[0032] It should be noted that, in this document, relational terms such as first and second (number one, number two), etc., are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0033] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.

Claims

1. An integrated thermostat cover, comprising a cover body made of a metal substrate (1), characterized in that: The surface of the metal substrate (1) in contact with the coolant is covered with a composite coating (2), which is composed of a bottom layer (8) and a top layer (9) with different functions. The bottom layer (8) is an inorganic conversion layer that is bonded to the metal substrate (1), and the top layer (9) is an organic polymer sealing layer that covers the bottom layer (8). An annular sealing groove (4) is provided on the connecting end face of the cover, and an integrated sealing ring (3) is interference-fitted into the annular sealing groove (4). The cross-section of the integrated sealing ring (3) is a double-lip structure. The integrated sealing ring (3) includes an annular mounting part (5) for fixing to the annular sealing groove (4), and a first annular lip (6) and a second annular lip (7) extending outward from the annular mounting part (5).

2. The integrated thermostat cover according to claim 1, characterized in that: The integrated sealing ring (3) is made of fluororubber or EPDM rubber.

3. The integrated thermostat cover according to claim 1, characterized in that: The metal substrate (1) is an aluminum alloy die casting.

4. An integrated thermostat cover according to claim 1, characterized in that: The inorganic conversion layer is an anodic oxide layer, a micro-arc oxide layer, or a ceramic conversion film layer.

5. An integrated thermostat cover according to claim 1, characterized in that: The organic polymer sealing layer is an epoxy resin layer, a fluorocarbon coating, or a polyurethane coating.

6. An integrated thermostat cover according to claim 1, characterized in that: The composite coating (2) also covers the outer surface of the metal substrate (1).

7. An integrated thermostat cover according to claim 1, characterized in that: The integrated sealing ring (3) has a Shore A hardness of 70 to 85 degrees.

8. An integrated thermostat cover according to claim 1, characterized in that: The total thickness of the composite coating (2) is 20 μm to 50 μm; wherein the thickness of the bottom layer (8) is 5 μm to 20 μm and the thickness of the top layer (9) is 10 μm to 30 μm.

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