Oil thermostat bypass assembly

Abstract

This invention relates to devices for regulating the temperature of oil in diesel engines. Conventional engines employ thermostats within the oil cooler housing to control oil temperature. Embodiments of the present invention provide a bypass assembly including a cap press fit against an internal wall of the oil cooler, an oil cooler attachment joined to the cap by a plurality of outwardly diverging legs, and flow openings between the legs that communicate with a lower opening of the attachment. A snap ring and gasket may be used to secure and seal the assembly. The bypass assembly contains no moving parts and is configured to continuously direct oil through the cooler, thereby reducing overheating and maintaining oil within a stable operating range. The assembly may be retrofitted into an oil cooler housing designed for a thermostat without modification.

Description

OIL THERMOSTAT BYPASS ASSEMBLYTECHNICAL FIELD

[0001] Embodiments of this invention relate to diesel engines.BACKGROUND ART

[0002] Prior to embodiments of the disclosed invention, diesel engines such as the Cummins ISX, QSX, and XI 5 series relied on thermostats within the oil cooler housing to regulate oil temperature. These thermostats included moving parts, such as wax-actuated valves and springs, that redirected oil flow depending on temperature. In practice, such thermostats were prone to failure, sticking, or delayed response, resulting in overheating of the engine oil, premature oil degradation, and elevated coolant temperatures. Embodiments of the disclosed invention solve these problemsDISCLOSURE OF THE INVENTION

[0003] The present invention relates to an oil thermostat bypass assembly for a diesel engine, as well as associated methods, systems, and kits. In one aspect, the invention provides an assembly comprising means for securing the assembly within an oil cooler, means for supporting the assembly within the oil cooler while defining a plurality of flow openings, and means for channeling oil through the plurality of flow openings and through a lower opening in order to bypass a thermostat. The assembly directs oil continuously through the oil cooler irrespective of oil temperature. The invention further encompasses embodiments in which the assembly includes means for retaining the assembly against an internal wall of the oil cooler, means for sealing the assembly to a header of the oil cooler, and means for supporting that comprise a plurality of legs arranged in a diverging configuration. In further embodiments, the means for channeling may include perforations, slots, or a mesh structure configured to permit continuous oil flow. The assembly may be formed as a unitary body lacking valves, springs, or other moving elements.

[0004]

[0005] In another aspect, the invention provides a structural assembly configured to direct cooling oil flow in a diesel engine. The assembly includes a cap press fit against an internal wall of an oil cooler, an oil cooler attachment joined to the cap by a plurality of legsand configured to couple to the oil cooler, a plurality of flow openings arranged between the plurality of legs, and a lower opening in the oil cooler attachment. Cooling oil travels between the plurality of flow openings and through the lower opening in order to bypass an oil thermostat. Dependent features of the assembly include the use of a snap ring to retain the cap in the internal wall, a gasket positioned between the oil cooler attachment and a header of the oil cooler, and a relative sizing in which the diameter of the cap is smaller than the diameter of the oil cooler attachment. The plurality of legs may extend outwardly from the cap toward the oil cooler attachment in a diverging configuration, may be equally spaced around the circumference of the cap, and may taper outwardly in width toward the oil cooler attachment. The cap, legs, and attachment may be formed as a unitary body. The plurality of flow openings may comprise perforations, slots, or a mesh structure configured to permit continuous oil flow. The assembly may lack valves, springs, or other moving elements, such that oil is continuously directed through the oil cooler across the operating temperature range of the diesel engine. The assembly may be made of stainless steel, aluminum, or a heat-resistant polymer.

[0006] In a further aspect, the invention provides a method of bypassing an oil thermostat in a diesel engine. The method comprises installing a bypass assembly comprising a cap, a plurality of legs, and an oil cooler attachment in an oil cooler housing in place of a thermostat, and directing engine oil through a plurality of flow openings arranged between the plurality of legs and through a lower opening in the oil cooler attachment such that engine oil is continuously routed through the oil cooler irrespective of oil temperature. The method may further comprise sealing the bypass assembly within the oil cooler housing using a gasket and retaining the cap in the internal wall of the oil cooler with a snap ring. In some embodiments, the bypass assembly is sized as a direct replacement for an oil thermostat in a Cummins ISX, QSX, or X15 diesel engine. In other embodiments, the bypass assembly is configured to maintain engine oil within a range of 200 to 235 degrees Fahrenheit during engine operation.

[0007] In another aspect, the invention provides a diesel engine comprising an oil cooler having an internal wall and an oil thermostat bypass assembly disposed within the oil cooler. The oil thermostat bypass assembly includes a cap press fit against the internal wall, an oil cooler attachment joined to the cap by a plurality of legs, a plurality of flow openings arranged between the plurality of legs, and a lower opening in the oil cooler attachment. Cooling oil travels between the plurality of flow openings and through the lower opening in order to bypass a thermostat, such that all engine oil is continuously directed through the oil cooler. In some embodiments, the oil thermostat bypass assembly further comprises a gasket positioned between the oil cooler attachment and the oil cooler header, or includes a snap ringthat retains the cap against the internal wall of the oil cooler. The oil thermostat bypass assembly may be retrofittable into an oil cooler housing designed for a thermostat without modification.

[0008] In yet another aspect, the invention provides a kit for bypassing a thermostat in a diesel engine. The kit comprises a bypass assembly including a cap, a plurality of legs, and an oil cooler attachment, together with a gasket sized to fit between the oil cooler attachment and a header of an oil cooler, and a snap ring configured to retain the cap in the internal wall of the oil cooler.BRIEF DESCRIPTION OF THE FIGURES

[0009] The detailed description of some embodiments of the invention is made below with reference to the accompanying figures, wherein like numerals represent corresponding parts of the figures.

[0010] FIG. 1 is an isometric view of a thermostat bypass assembly.

[0011] FIG. 2 is a top plan view of the assembly showing a cap, legs, and flow openings.

[0012] FIG. 3 is a bottom plan view showing an oil cooler attachment, a lower opening, and a gasket seat.

[0013] FIG. 4 is a sectional view of the assembly installed in an oil cooler housing.

[0014] FIG. 5 is an enlarged detail view illustrating a snap ring engaged in a groove.

[0015] FIG. 6 is an alternate embodiment including diverging legs and slot openings.

[0016] FIG. 7 is a flowchart illustrating a method of installing the bypass assembly..BEST MODE OF THE INVENTION

[0017] By way of example, and referring to FIG. 1, one embodiment of the present system comprises The following description sets forth various embodiments of an oil thermostat bypass assembly 10 configured for use in diesel engines. The assembly 10 is designed to be installed in place of a factory-installed thermostat 42 within an engine oil cooler housing 44. In contrast to conventional designs that rely on a thermostatic element to regulate oil flow based on temperature, the bypass assembly 10 continuously directs oil through the oil cooler, thereby eliminating moving parts associated with thermostatic regulation. This designreduces the likelihood of mechanical failure, provides more stable oil cooling, and simplifies maintenance and retrofitting.

[0018] As shown in FIG. 1, the assembly 10 includes a cap 12 sized for interference engagement against an internal wall 14 of the oil cooler housing 44. The cap 12 may have a generally circular profile with an outer diameter selected to achieve a press fit within a corresponding bore of the housing. The upper surface of the cap 12 may be planar, domed, or convex, and is configured to obstruct upward oil flow paths, thereby forcing oil to pass through the flow passages formed below. In certain embodiments, the cap 12 incorporates retention features to improve seating and stability.

[0019] Retention of the cap 12 within the housing 44 may be provided by a snap ring 16 seated in a circumferential groove 18 formed in the internal wall 14, as shown in FIG. 5. When engaged, the snap ring 16 captures the cap 12 and resists axial displacement. In other embodiments, retention may be achieved using an annular flange extending radially from the cap 12, locking tabs that engage recesses in the wall, or a threaded connection.

[0020] A plurality of legs 20 extend from the cap 12 to an oil cooler attachment 24 located below. The legs 20 provide structural support and, in cooperation with the cap 12 and the attachment 24, define a plurality of flow openings 22. The flow openings 22 constitute primary oil passages for the assembly 10. As depicted in FIGS. 1-3, the legs 20 may be equally spaced about the circumference of the cap 12, and may exhibit straight, tapered, or diverging configurations 32. In some embodiments, the legs 20 taper outwardly in width toward the oil cooler attachment 24. In other embodiments, the legs 20 may have uniform thickness or variable curvature to optimize both strength and oil flow.

[0021] The oil cooler attachment 24 forms the lower portion of the assembly 10 and interfaces directly with the oil cooler header 30. In one embodiment shown in FIG. 3, the attachment 24 includes a central lower opening 26 aligned with the primary oil flow path. Oil descending through the flow openings 22 passes through the lower opening 26 to enter the cooler. The attachment 24 may present a washer-like geometry or a stepped shoulder that ensures registration against the header 30.

[0022] A gasket 28 is disposed between the oil cooler attachment 24 and the oil cooler header 30 to provide sealing. The gasket 28 may be elastomeric, metallic, or composite. Compression occurs when the attachment 24 is seated against the header 30, as shown in FIG. 4. In some embodiments, an O-ring groove may be provided in the attachment 24 to improve sealing, while in other embodiments a raised sealing ridge or bonded gasket may be used.

[0023] In one version, the outer diameter of the cap 12 is smaller than the outer diameter of the attachment 24, producing a stepped geometry that aids seating. As shown in FIG. 6, the flow openings 22 can incorporate slot features 34, perforations, or a mesh screen. In some embodiments, the assembly 10 is fabricated as a single-piece CNC-machined unit 36. In other embodiments, the cap 12, legs 20, and attachment 24 are fabricated separately and joined together by welding, brazing, or mechanical fastening. Suitable materials 38 include stainless steel, aluminum, or high-temperature polymers. In some versions, the assembly 10 may be formed of carbon steel for cost efficiency, or of advanced composites to reduce weight.

[0024] When installed, the assembly 10 replaces the thermostat 42 within the housing 44. Oil entering the cooler housing is blocked from bypass routes by the cap 12 and attachment 24, and is instead directed through the flow openings 22 and lower opening 26. This ensures continuous flow through the oil cooler irrespective of oil temperature, maintaining oil within a preferred range and eliminating failure modes associated with thermostatic elements.

[0025] In some embodiments, the snap ring 16 is replaced by an annular flange integral with the cap 12.

[0026] In some embodiments, the gasket 28 is formed of an elastomer such as nitrile rubber. In other embodiments, the gasket 28 is metallic, for example copper or aluminum, or a multi-layer composite for high-temperature service.

[0027] In some embodiments, the flow openings 22 comprise uniformly spaced slots, while in other embodiments they comprise perforations or a woven mesh insert.

[0028] In some embodiments , the legs 20 diverge outwardly from the cap 12 toward the oil cooler attachment 24, as illustrated in FIG. 6. In other embodiments, the legs 20 are straight and parallel.

[0029] In some embodiments, the entire assembly 10 is formed as a one-piece unitary structure. In other embodiments, the cap 12, legs 20, and attachment 24 are discrete components joined together by welding or fastening.

[0030] In some embodiments, the assembly 10 is made of stainless steel for corrosion resistance. In other embodiments, the assembly 10 is made of aluminum for reduced weight, or of heat-resistant polymers for ease of manufacture.

[0031] In some embodiments, the assembly 10 is dimensioned as a direct replacement for a thermostat in Cummins ISX, QSX, or XI 5 diesel engines, thereby facilitating aftermarket installation. In other embodiments, the assembly 10 is scaled for use in other heavy-duty or medium-duty diesel platforms.

[0032] A method of installing the thermostat bypass assembly 10 into an engine oil cooler is illustrated in FIG. 7. The method includes disconnecting the vehicle batteries, loosening the drive belts, and removing the alternator. The air conditioning compressor is then unbolted and temporarily repositioned on the valve cover. The main tensioner pulley is removed, followed by unbolting of the accessory bracket and fan shroud bracket. The accessory bracket is taken out of the engine compartment to provide access to the oil cooler.

[0033] The end cap of the oil cooler is removed, and snap ring pliers are used to release the snap ring 16 from the groove 18 in the internal wall 14, thereby freeing the thermostat 42. The thermostat 42 is withdrawn from the bore of the housing 44. The bypass assembly 10 is then installed in its place, with the cap 12 seated within the internal wall 14, the snap ring 16 securing the cap 12, and the oil cooler attachment 24 and gasket 28 sealing against the header 30.

[0034] Finally, the previously removed components are reinstalled in reverse order. Once complete, the engine may be operated with oil continuously routed through the cooler, thereby maintaining reduced and stable oil temperatures and eliminating reliance on thermostatic regulation.

[0035] Persons of ordinary skill in the art may appreciate that numerous design configurations may be possible to enjoy the functional benefits of the inventive systems. Thus, given the wide variety of configurations and arrangements of embodiments of the present invention the scope of the invention is reflected by the breadth of the claims below rather than narrowed by the embodiments described above.INDUSTRIAL APPLICABILITY

[0036] Embodiments of the disclosed invention can bypass an oil thermostat for a diesel engine.

Claims

WHAT IS CLAIMED IS:

1. An oil thermostat bypass assembly for a diesel engine, comprising: means for securing the assembly within an oil cooler; means for supporting the assembly within the oil cooler while defining a plurality of flow openings; and means for channeling oil through the plurality of flow openings and through a lower opening in order to bypass a thermostat, wherein the assembly directs oil continuously through the oil cooler irrespective of oil temperature.

2. The assembly of claim 1, further comprising means for retaining the assembly against an internal wall of the oil cooler.

3. The assembly of claim 1 , further comprising means for sealing the assembly to a header of the oil cooler.

4. The assembly of claim 1 , wherein the means for supporting comprise a plurality of legs arranged in a diverging configuration.

5. The assembly of claim 1, wherein the means for channeling include perforations, slots, or a mesh structure configured to permit continuous oil flow.

6. The assembly of claim 1 , wherein the assembly is a unitary body lacking valves, springs, or other moving elements.

7. A jacket oil cooling bypass thermostat bypass assembly configured to direct cooling oil flow in a diesel engine, the assembly comprising: a cap press fit against an internal wall of an oil cooler; an oil cooler attachment joined to the cap by a plurality of legs, the oil cooler attachment being configured to couple to the oil cooler; a plurality of flow openings arranged between the plurality of legs; and a lower opening in the oil cooler attachment,wherein cooling oil travels between the plurality of flow openings and through the lower opening in order to bypass an oil thermostat.

8. The assembly of claim 7, further comprising a snap ring configured to retain the cap in the internal wall of the oil cooler.

9. The assembly of claim 7, further comprising a gasket positioned between the oil cooler attachment and a header of the oil cooler.

10. The assembly of claim 7, wherein a diameter of the cap is smaller than a diameter of the oil cooler attachment.

11. The assembly of claim 7, wherein the plurality of legs extend outwardly from the cap toward the oil cooler attachment in a diverging configuration.

12. The assembly of claim 7, wherein the cap, the legs, and the oil cooler attachment are formed as a unitary body.

13. The assembly of claim 7, wherein the plurality of flow openings comprise perforations, slots, or a mesh structure configured to permit continuous oil flow.

14. The assembly of claim 7, wherein the assembly lacks valves, springs, or other moving elements, such that oil is continuously directed through the oil cooler across an operating temperature range of the diesel engine.

15. The assembly of claim 7 , wherein the plurality of legs are equally spaced around a circumference of the cap.

16. The assembly of claim 7, wherein the plurality of legs taper outwardly in width toward the oil cooler attachment.

17. The assembly of claim 7, wherein the oil thermostat bypass assembly is made of stainless steel, aluminum, or a heat-resistant polymer.

18. A method of bypassing an oil thermostat in a diesel engine, the method comprising: installing a bypass assembly comprising a cap, a plurality of legs, and an oil cooler attachment in an oil cooler housing in place of a thermostat; and directing engine oil through a plurality of flow openings arranged between the plurality of legs and through a lower opening in the oil cooler attachment, such that engine oil is continuously routed through the oil cooler irrespective of oil temperature.

19. The method of claim 18, further comprising sealing the bypass assembly within the oil cooler housing using a gasket.

20. The method of claim 18, wherein installing the bypass assembly includes retaining the cap in the internal wall of the oil cooler with a snap ring.

21. The method of claim 18, wherein the bypass assembly is sized as a direct replacement for an oil thermostat in a Cummins 1SX, QSX, or XI 5 diesel engine.

22. The method of claim 18, wherein the bypass assembly is configured to maintain engine oil within a range of 200 to 235 degrees Fahrenheit during engine operation.

23. A diesel engine comprising: an oil cooler having an internal wall; and an oil thermostat bypass assembly disposed within the oil cooler, the oil thermostat bypass assembly including a cap press fit against the internal wall, an oil cooler attachment joined to the cap by a plurality of legs, a plurality of flow openings arranged between the plurality of legs, and a lower opening in the oil cooler attachment, wherein cooling oil travels between the plurality of flow openings and through the lower opening in order to bypass a thermostat, such that all engine oil is continuously directed through the oil cooler.

24. The diesel engine of claim 23, wherein the oil thermostat bypass assembly further comprises a gasket positioned between the oil cooler attachment and the oil cooler header.

25. The diesel engine of claim 23, wherein the oil thermostat bypass assembly includes a snap ring that retains the cap against the internal wall of the oil cooler.

26. The diesel engine of claim 23, wherein the oil thermostat bypass assembly is retrofittable into an oil cooler housing designed for a thermostat without modification to the oil cooler housing.

27. A kit for bypassing a thermostat in a diesel engine, comprising: a bypass assembly including a cap, a plurality of legs, and an oil cooler attachment; a gasket sized to fit between the oil cooler attachment and a header of an oil cooler; and a snap ring configured to retain the cap in the internal wall of the oil cooler.

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