Coolant Thermostat Rectifier Layout for Lower Flow Resistance
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Solution Overview
Problem
The existing thermostat devices for internal combustion engines experience increased flow resistance and pressure loss due to the spring receiving frame and frame support structures, which impede coolant flow and require larger water pumps, leading to cost and efficiency issues.
Innovation Solution
A thermostat device design that incorporates a locking portion on the spring receiving frame, locked to a frame support, and a rectifier positioned upstream in the coolant flow to bypass collisions, combined with a cone-shaped coil spring and a narrow spring receiving frame to minimize flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring receiving frame and frame support are formed in the housing to support the control valve, then the control valve can be reliably biased and positioned, but the flow resistance and pressure loss of the coolant increase due to the perpendicular placement of these components
Solution Approach 1:
The frame support is repositioned from a perpendicular placement (causing flow obstruction) to an upstream placement along the coolant flow direction. The rectifier component is introduced to guide the coolant flow in another dimension, allowing it to bypass the frame support and spring receiving frame without collision, thus reducing flow resistance while maintaining structural support function
Solution Approach 2:
A rectifier component is introduced as an intermediary element between the coolant flow and the frame support/spring receiving frame. This rectifier mediates the interaction by redirecting the coolant flow path, preventing direct collision with the support structures while maintaining their positioning function for the control valve
2Device complexity
If the spring receiving frame and frame support are placed perpendicular to the coolant passage, then the control valve structure can be simplified, but turbulence and stagnation of coolant occur increasing pressure loss
Solution Approach 1:
The coolant flow path is made dynamic and adaptable by introducing the rectifier that can redirect flow as needed. The frame support and spring receiving frame maintain their simplified perpendicular structure, while the rectifier dynamically adjusts the coolant flow direction to bypass these structures, preventing turbulence and stagnation
3Reliability
If additional members such as coil spring and spring receiving frame are added to the thermal-operating unit, then the control valve can be effectively biased to closed state, but the device complexity and manufacturing cost increase
Solution Approach 1:
The spring receiving frame is merged with the frame support structure, integrating two functions into a single component. The rectifier is also integrated into the housing structure, combining flow guidance with the housing function, thereby reducing the number of separate parts while maintaining the biasing and support functions
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 design reduces flow resistance and pressure loss by detouring coolant flow around the frame support and spring receiving frame, smoothing coolant flow and reducing the size of the spring receiving frame, thereby enhancing coolant circulation efficiency and reducing costs.
Implementation Method 1
a thermal expansion body (wax) which expands or contracts due to the temperature change of a coolant
Data Source
AI summary
Provided is a thermostat device capable of reducing flow resistance due to a thermal-operating unit and a frame support and also reducing the pressure loss in the flow passage. The thermostat device is provided with a control valve which opens and closes a flow passage in a housing based on expansion or contraction of a thermal expansion body in a thermo-sensitive element and a spring that biases the control valve to close and a spring receiving frame that receives one end of the spring. A thermal-operating unit is incorporated into the housing by locking the spring receiving frame to the frame supports formed in the flow passage of the housing. At the upstream side of the coolant flow at the frame support, a rectifier is disposed that prevents water streams from colliding by detouring the flow passage of the coolant heading to the frame support and the spring receiving frame.