Engine Coolant Tank Mechanical Coupling Design
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Solution Overview
Problem
Existing supplementary tanks for internal combustion engine auxiliary systems face limitations in design due to hot welding requirements, restricting the height of the stilling well, preventing use of different materials, and increasing manufacturing complexity and costs.
Innovation Solution
The tank uses mechanical coupling with elastic teeth and adhesive material to connect half-shells, allowing for longer stilling wells, use of different materials, and varied coupling edge configurations without the drawbacks of hot welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If hot welding is used to connect half-shells, then strong connection is achieved, but the stilling well height is limited
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical coupling system consisting of coupling elements that engage with recesses in the half-shells. This mechanical coupling allows the stilling well to extend to the upper surface of the upper half-shell without being constrained by welding process limitations, as the coupling elements can accommodate protruding features that would interfere with hot blade welding.
2Adaptability or versatility
If hot welding is used to connect half-shells, then rigid connection is achieved, but material selection is restricted
Solution Approach 1:
By substituting thermal welding with mechanical coupling, the patent enables the use of different thermoplastic materials for the upper and lower half-shells that may not be compatible with hot welding. The mechanical coupling elements and recesses can be molded into half-shells made of various materials including polypropylene, polyamide, or other engineering plastics without requiring material compatibility for thermal bonding.
3Reliability
If hot welding is used to connect half-shells, then strong bond is achieved, but process control difficulty increases
Solution Approach 1:
The mechanical coupling system replaces the thermally-controlled welding process with a mechanically-controlled assembly process. The coupling elements feature elastic teeth that engage with corresponding recesses, providing inherent mechanical interlocking and positioning. This eliminates the need for precise temperature control, heating time management, and weld parameter optimization required in hot welding processes.
4Adaptability or versatility
If mechanical coupling with elastic teeth is used, then design flexibility is improved, but connection strength may be reduced
Solution Approach 1:
The patent combines mechanical coupling with adhesive bonding to achieve both design flexibility and strong connection. The mechanical coupling elements provide structural interlocking and positioning, while adhesive material fills the gaps between coupling elements and recesses, creating a composite joint that leverages both mechanical interlocking and chemical bonding for superior strength and flexibility.
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 enables efficient manufacturing with flexible design options, including different materials and configurations, enhancing operational efficiency and simplifying assembly line operations.
Implementation Method 1
The perimetral coupling edges of the upper half-shell and the lower half-shell are rigidly connected to each other by means of adhesive material
Implementation Method 2
with the aid of a plurality of elastic teeth each protruding from one of said half-shells and engaged within corresponding coupling seats of the other half-shell
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A supplementary tank (1) for an auxiliary system associated with an internal combustion engine of a motor-vehicle, having a containing volume (7) for the coolant of an engine cooling system, or two separate containing volumes (7, 70), one for the coolant and the other for a urea solution in a catalytic reduction system of the exhaust gases of the engine, wherein said supplementary tank (1) has a body (2) comprising an upper half-shell (3) and a lower half-shell (4), both made of plastic, rigidly connected to each other along respective perimetral coupling edges (3A, 4A) and defining the aforesaid containing volume (7) or the aforesaid containing volumes (7, 70) between them, wherein said containing volume (7) or each of said containing volumes (7, 70) is provided with a filling inlet (10, 100) for filling the fluid within the containing volume, and at least one upper connection element (5) and one lower connection element (6) for connecting ducts to said auxiliary system, and wherein said containing volume (7) of the coolant is associated with a stilling well (8), extending upwards within said containing volume (7) of the coolant starting from a bottom wall of said body (1), said supplementary tank being characterized in that said upper half-shell (3) and said lower half-shell (4) are rigidly connected to each other by means of adhesive material, and in that said stilling well (8) protrudes upwards beyond a theoretical plane containing the perimetral coupling edge (4A) of the lower half-shell and in that said stilling well (8) is formed in a single piece with said lower half-shell (4).