Coolant Manifold with Variable Flow Paths for Tractor-Trailers
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Solution Overview
Problem
Conventional diesel engine cooling systems in tractor-trailer trucks require multiple separate connections and extensive piping, leading to increased costs, weight, maintenance needs, and suboptimal coolant flow distribution due to differing thermal requirements of components.
Innovation Solution
A coolant manifold with pre-selected internal flow paths and ports that distribute coolant efficiently to various heat sources and sinks, reducing the number of connections and piping length while optimizing coolant flow rates based on thermal requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cooling systems and plumbing are used for each thermal component, then each component can be independently connected to the engine block, but the system cost, weight, and maintenance requirements increase significantly
Solution Approach 1:
The patent consolidates multiple separate cooling systems and plumbing connections into a single integrated coolant manifold assembly. The manifold provides multiple ports that connect to different thermal components (fuel filter heater, cab heater, diesel exhaust fluid injector) while sharing common supply and return lines to the engine block, thereby reducing the total weight of piping and hoses required.
Solution Approach 2:
The coolant manifold serves multiple functions simultaneously: it acts as a distribution hub for coolant supply to various thermal components, a collection point for return lines, and a flow regulation device with internal restrictions. This multi-functional design eliminates the need for separate dedicated plumbing for each component, reducing overall system weight while maintaining independent connection capability.
2Reliability
If multiple separate pipe or hose connections are used for each thermal component, then each component receives coolant, but the piping length and material costs increase significantly
Solution Approach 1:
The manifold combines multiple separate pipe connections into a single centralized component. Instead of running individual hoses from the engine block to each thermal component, the manifold provides a central connection point with multiple ports, significantly reducing the total length of piping and hoses required while ensuring reliable coolant delivery to all components.
Solution Approach 2:
The coolant manifold acts as an intermediary device between the engine block and multiple thermal components. It receives coolant from the engine block through a single supply line and distributes it to various components through internal passages, eliminating the need for long external hoses and reducing overall piping length while maintaining reliable coolant flow.
3Ease of manufacture
If uniform coolant flow is provided to all thermal components, then the system is simpler to design, but components with differing thermal requirements do not receive optimal coolant flow rates
Solution Approach 1:
The manifold incorporates local variations in flow characteristics through internal restrictions of different sizes positioned at specific ports. Each thermal component receives customized coolant flow rates according to its thermal requirements: the fuel filter heater receives higher flow rates, while the cab heater and diesel exhaust fluid injector receive lower flow rates, optimizing thermal management for each component.
Solution Approach 2:
The patent modifies the coolant flow parameters by incorporating internal restrictions with varying dimensions within the manifold. These restrictions change the flow rate and pressure characteristics of coolant delivered to different ports, allowing precise control over coolant distribution to match the thermal requirements of each connected component while maintaining a simple integrated design.
4Adaptability or versatility
If extensive piping and hoses are run through the engine compartment, then all thermal components can be connected, but the maintenance frequency increases due to wear and tear
Solution Approach 1:
The manifold merges multiple separate hose and pipe connections into a single centralized component with integrated ports. This reduces the total number of connection points and length of flexible hoses required, thereby reducing wear and tear from vibration and rubbing, and lowering maintenance frequency while preserving the ability to connect to all thermal components.
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 coolant manifold reduces the number of connections by half, decreases piping length and weight, lowers maintenance costs, and improves fuel economy by optimizing coolant flow distribution, resulting in significant fuel savings over the truck's service life.
Implementation Method 1
The manifold can have internal flow paths configured so that coolant flow rate or pressure exiting one supply port is different from the coolant flow rate or pressure exiting from another supply port
Implementation Method 2
The redistributed heat can be used beneficially by for example directing the heat to components that require heat to properly function
Data Source
AI summary
A tractor-trailer truck engine coolant manifold comprises a first supply port for receiving coolant from an engine or radiator, and a first return port for returning coolant to the engine or radiator. The manifold also has a second supply port in fluid communication with the first supply port, and a second return port in fluid communication with the first return port. Further, the manifold can have a third supply port in fluid communication with the first supply port, and a third return port in fluid communication with the first return port. The coolant manifold can further have one or more internal flow paths that are configured so that coolant flow rate or pressure exiting one supply port is different from the coolant flow rate or pressure exiting from another supply port, pre-selected based upon the thermal requirements of the heat source or heat sink components.