Dual-Phase Coated Throttle Body for Deposit-Resistant Airflow
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Solution Overview
Problem
Throttle bodies in vehicles experience deposit accumulation, leading to restricted airflow and mechanical issues, increasing warranty costs, and existing algorithmic methods for airflow control have practical limitations.
Innovation Solution
A throttle body with a dual-phase thermal composite coating (TCC) applied to both the inner surface and moveable blade valve, comprising a hydrophobic material and a thermal conductive material, enhancing thermal conductivity and reducing deposit accumulation by regulating air flow and repelling moisture and hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional throttle body is used, then the structure is simple and manufacturing is easy, but deposit accumulation occurs leading to restricted airflow and mechanical issues
Solution Approach 1:
The patent applies a dual-phase thermal composite coating comprising a first material (e.g., polymer matrix) and a second material (e.g., thermal conductive particles like aluminum oxide or copper) in specific weight percentages. This composite structure provides both hydrophobic properties to prevent deposit accumulation and thermal conductivity to manage heat, resolving the contradiction between reliability and complexity by using material composition rather than mechanical structural changes.
Solution Approach 2:
The patent modifies surface properties by changing the chemical composition and physical parameters of the coating materials. The first material provides hydrophobicity with contact angles optimized to repel deposits, while the second material adjusts thermal conductivity parameters. This parameter-based approach enables the coating to simultaneously achieve deposit resistance and thermal management without complex mechanical structures.
2Productivity
If the throttle body operates for extended periods, then production increases, but deposit accumulation leads to mechanical issues and warranty costs
Solution Approach 1:
The dual-phase thermal composite coating is applied in advance to the throttle body surfaces before operation begins. The coating pre-establishes hydrophobic barriers and thermal management capabilities that prevent deposit accumulation from occurring during extended operation, rather than addressing deposits after they form. This preliminary protective action enables prolonged productivity while maintaining mechanical reliability.
Solution Approach 2:
The patent converts the harmful effect of heat and moisture (which contribute to deposit formation) into beneficial effects. The hydrophobic first material repels moisture that would otherwise promote deposits, while the thermal conductive second material transforms heat that could accelerate degradation into effective thermal management. This converts potentially harmful environmental factors into protective mechanisms that extend operational duration while maintaining reliability.
3Reliability
If a single-material coating is used, then manufacturing is simpler, but thermal conductivity and deposit resistance cannot be optimized simultaneously
Solution Approach 1:
The patent combines two distinct materials with complementary properties in a single composite coating system. The first material (polymer matrix) provides hydrophobicity and adhesion, while the second material (thermal conductive particles such as aluminum oxide, copper, or zinc oxide) provides thermal conductivity. This composite approach enables simultaneous optimization of both deposit resistance and thermal management in one coating application process, maintaining ease of manufacture while achieving superior performance.
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
The dual-phase TCC effectively reduces deposit accumulation and enhances thermal conductivity, ensuring optimal performance and longevity of the throttle body by improving airflow regulation and thermal management.
Implementation Method 1
The first material comprises between 10 weight percent (wt %) and 90 wt % and the second material comprising between 10 wt % and 90 wt % of the dual-phase TCC. The dual phase TCC has a contact angle of between 100 degrees (°) and 160°
Implementation Method 2
The dual phase TCC has a contact angle of between 100 degrees (°) and 160° and a thermal conductivity of at least 0.3 W/mK
Data Source
AI summary
A throttle body for an engine or fuel cell of a vehicle is provided. The throttle body comprises a cylindrical housing comprising a first open end extending to a second open end defining an inner wall having an inner surface. The throttle body further comprises a moveable blade valve movably disposed on the inner wall and arranged to regulate air to the engine during operation of the vehicle. The moveable blade valve has an outer surface. The throttle body further comprises a dual-phase thermal composite coating (TCC) disposed on one of the inner surface of the inner wall and outer surface of the moveable blade valve for enhanced thermal conductivity and reduced deposit accumulation on the inner surface and the outer surface. The dual-phase TCC comprises a first material comprising between 10 wt % and 90 wt %, and a second material comprising between 10 wt % and 90 wt % of the dual-phase TCC. The dual phase TCC has a contact angle of between 100° and 160° and a thermal conductivity of at least 0.3 W/mK.