Integrated Coolant Filler Neck for Compact Overflow Management

Solution Overview

Problem

Conventional coolant overflow systems in vehicles result in increased size and manufacturing costs due to the remote location of overflow and makeup reservoirs, necessitating additional tubes or hoses, which also increase weight.

Innovation Solution

A coolant filler neck assembly with an integrated coolant overflow reservoir that includes a cylinder housing with internal fluid conduits for overflow management, eliminating the need for external connections and reducing overall size and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a remote overflow and makeup reservoir is used, then coolant overflow management is effective, but the overall size and weight of the system increase

Engineering Contradiction:

Improvecoolant overflow managementVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines the overflow reservoir and makeup reservoir functions into the filler neck assembly itself, eliminating the need for a separate remote reservoir. The filler neck contains internal passages that serve as both the overflow management system and the makeup reservoir, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filler neck assembly performs multiple functions: it serves as the filler opening, contains the overflow reservoir, provides overflow management through internal passages, and acts as the makeup reservoir. This multi-functional design eliminates the need for separate dedicated overflow and makeup components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a remote overflow and makeup reservoir is used, then coolant overflow management is effective, but manufacturing costs increase

Engineering Contradiction:

Improvecoolant overflow managementVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the overflow reservoir and makeup reservoir functions into the filler neck assembly itself, eliminating the need for a separate remote reservoir. The filler neck contains internal passages that serve as both the overflow management system and the makeup reservoir, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If external tubes or hoses are used to connect the reservoir, then coolant flow is managed, but the assembly size and weight increase

Engineering Contradiction:

Improvecoolant flow managementVSAvoidassembly size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent combines the overflow reservoir and makeup reservoir functions into the filler neck assembly itself, eliminating the need for a separate remote reservoir. The filler neck contains internal passages that serve as both the overflow management system and the makeup reservoir, merging multiple functions into a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

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 integrated design minimizes the assembly's size and weight while maintaining efficient coolant overflow and expansion management, thereby reducing manufacturing costs.

Implementation Method 1

Coolant expands as the system warms... As the system cools, the coolant contracts

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12503972B2Coolant filler neck assembly having integrated coolant overflow reservoir

Publication Date: 2025.12.23 HARLEY DAVIDSON MOTOR CO INC

AI summary

A coolant filler neck assembly for a pressurized cooling system. The coolant filler neck includes a cylinder housing defining a non-pressurized coolant overflow reservoir; an upper cap member attached to an upper region of the cylinder housing, the upper cap member including an overflow inlet port member arranged internally in the coolant overflow reservoir and a filler pipe member in fluidic communication with the overflow inlet port member and the pressurized cooling system; a first fluid overflow tube member arranged internally in the coolant overflow reservoir to extend in a longitudinal direction though a first region of the non-pressurized coolant overflow reservoir to direct overflow liquid coolant to the non-pressurized coolant overflow reservoir; and a second fluid overflow tube member arranged internally in the coolant overflow reservoir to extend in a longitudinal direction though a second region of the non-pressurized coolant overflow reservoir to direct the overflow liquid coolant from the non-pressurized coolant overflow reservoir to the ambient environment.