Continuous Cooler Flow Valve for Vehicular Transmission Lubrication
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Solution Overview
Problem
Thermostatically controlled bypass valves in vehicle transmissions fail to open at low temperatures, leading to potential damage and overheating of gears, particularly the overdrive sun and planet gears, due to inadequate lubricant flow.
Innovation Solution
A continuous cooler flow and safety bypass valve system that ensures lubricant flow from the torque converter to the cooler circuit at all temperatures, with a safety blow-off valve that directs flow to the lube circuit if pressure rises, and modifications such as removing the dump ball valve and enlarging orifices to increase lubricant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a thermostatically controlled bypass valve is used to prevent cooler flow at low temperatures, then energy loss is reduced, but reliability deteriorates because the valve may fail to open at the correct temperature
Solution Approach 1:
The patent removes the thermostatic control mechanism from the bypass valve, extracting the problematic temperature-dependent control element. This eliminates the reliability issue of thermostatic switch failure while maintaining the energy-saving bypass function through a permanently open design with alternative safety mechanisms.
Solution Approach 2:
The patent provides beforehand cushioning by incorporating a safety bypass mechanism that activates under extreme conditions. The safety bypass valve and alternative flow paths are pre-configured to prevent complete flow blockage if the main cooler circuit fails, protecting against catastrophic gear damage while allowing normal operation through the primary bypass.
2Device complexity
If a thermostatically controlled bypass valve is used to prevent cooler flow at low temperatures, then device complexity is reduced, but harmful factors increase due to potential gear damage from inadequate lubrication
Solution Approach 1:
The patent extracts the thermostatic control mechanism that causes both complexity and potential harm. By using a permanently open bypass valve without temperature-sensitive components, the design simplifies the system while eliminating the risk of valve failure that could lead to gear damage from inadequate lubrication.
Solution Approach 2:
The patent implements beforehand cushioning through safety bypass provisions that prevent harmful effects before they occur. The safety bypass valve and alternative flow paths are pre-configured to ensure continuous lubrication flow under all conditions, protecting gears from damage even if the main cooler circuit becomes blocked.
3Temperature
If maximum flow to the cooler circuit is provided when the bypass valve opens, then temperature control is improved, but productivity decreases because overdrive gears receive insufficient lubricant flow
Solution Approach 1:
The patent segments the lubrication flow into multiple independent paths: a primary bypass path for maximum cooler flow and alternative safety paths that can divert flow to overdrive gears. This segmentation allows the system to optimize cooler cooling while providing dedicated flow paths for gear lubrication, preventing the zero-sum trade-off between cooler flow and gear lubrication.
Solution Approach 2:
The patent provides beforehand cushioning by pre-configuring alternative flow paths and safety bypass mechanisms that ensure overdrive gears receive adequate lubrication. These safety provisions are built into the system architecture before any potential failure occurs, ensuring continuous protection for vulnerable gears while maintaining optimal cooler flow during normal operation.
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
This solution provides continuous lubricant flow to the cooler circuit at startup temperatures and automatically bypasses to the lube circuit when pressure increases, preventing gear damage by ensuring adequate lubrication and up to a 300% increase in lubricant flow to the cooler circuit.
Implementation Method 1
Upon build up of pressure within the inlet openings, the safety valve is forced open allowing flow into the valve chamber
Implementation Method 2
The safety valve is normally biased to close the flow passage opening to prevent flow into the valve chamber
Data Source
AI summary
An apparatus and method of providing a continuous flow of discharge transmission fluid from a torque converter to a cooler of a vehicle transmission such that oil flow to the cooler begins at engine start up and wherein the apparatus includes a safety bypass valve that directs discharge from the torque converter directly to a lube circuit other, than the cooler circuit, in the event pressure within the cooler circuit rises above a predetermine pressure due to a gelling of lubricant oil or other clogging of the cooler circuit.