Flared-End Coolant Pipe Stent Repair for Engine Front Seal Leaks
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Solution Overview
Problem
Existing methods for repairing leaking coolant transfer pipes in automotive engines, such as those in BMW N62 engines, are costly and time-consuming, often requiring the removal of major engine components like the intake manifold and timing chain cover, and can result in recurring leaks at the front seal.
Innovation Solution
A repair kit and method involving a flared-end stent and sealant are used to create a watertight seal within the engine block, allowing for the repair of leaking coolant transfer pipes without removing the intake manifold or timing chain cover, utilizing a repair tube insert coated with high-temperature sealant to bond with the engine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods are used to repair leaking coolant transfer pipes, then the leak can be stopped, but the repair requires removal of major engine components (intake manifold and timing chain cover), resulting in high labor costs and extended repair time
Solution Approach 1:
The invention extracts the repair function from the traditional comprehensive disassembly approach. Instead of removing the intake manifold and timing chain cover to access and replace the entire coolant transfer pipe assembly, the repair method extracts only the defective section and applies a localized repair stent through accessible openings, thereby stopping the leak without the time-consuming removal of major engine components
Solution Approach 2:
The repair stent is segmented into functional zones: a flared end section for sealing against the coolant passage wall, a cylindrical intermediate section for structural support, and an open end for coolant flow. This segmentation allows the repair component to be inserted through limited access openings and perform multiple functions (sealing, supporting, flowing) without requiring complete disassembly of the engine
2Reliability
If traditional repair methods are used, then leaks can be addressed, but the process is costly and time-consuming
Solution Approach 1:
The repair stent is designed as a cost-effective, single-use component that can be installed without expensive specialized equipment or extensive labor. The stent provides sufficient service life to address the leak problem economically, replacing only the defective function rather than requiring expensive replacement of entire engine assemblies or major components
Solution Approach 2:
The repair stent applies local quality by concentrating sealing and structural functions only where needed within the coolant passage. The flared end provides localized sealing at the coolant passage opening, while the cylindrical section provides localized structural support, avoiding the need for comprehensive replacement of the entire coolant transfer pipe system
3Reliability
If a repair solution is implemented, then coolant flow should be maintained, but the repair area must be sealed to prevent leaks
Solution Approach 1:
The repair stent employs a flexible yet structurally sound design where the thin-walled cylindrical section allows coolant to flow through while the flared end section creates a seal against the coolant passage wall. The material and geometry are optimized to provide sealing function without creating excessive flow resistance, maintaining coolant flow efficiency while preventing leaks at the repair location
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 approach provides a durable, cost-effective, and time-saving solution that stops coolant leaks at the front seal, reducing labor costs and repair time, and can be performed by skilled DIY owners, ensuring the engine block remains sealed without blocking coolant flow.
Implementation Method 1
a flared portion for contacting the coolant passage at an expansion of the coolant passage at a first end
Implementation Method 2
a package of coolant pipe repair sealant for affixing the repair stent within the coolant passage
Data Source
AI summary
A repair kit and associated method for repairing an automotive coolant pipe for fluid-conducting within an engine block of an engine includes at least a repair stent with a flared end, sealant and instructions for performing the method. The method includes draining coolant from the engine, removing the water pump from the engine without removing the timing chain cover of the engine, inserting the repair stent including a sealant through the coolant passage, wherein the coolant passage extends through the timing chain cover into the engine, re-assembling the water pump to the engine and adding coolant to the engine.