Fluid-Actuated Coolant Valve for High-Flow DEF Thawing
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Solution Overview
Problem
Conventional coolant control valves in diesel vehicles have limited flow factors and debris tolerances, leading to potential emissions-related failures and overheating due to leakage when operating in cold conditions.
Innovation Solution
A fluid actuated normally closed coolant control valve with a fluid actuated piston and biasing element, providing a flow factor greater than 1.5 and increased debris tolerance by being withdrawn from the valve chamber in the open condition, allowing for higher flow rates and reduced thaw time of Diesel Emission Fluid (DEF) while preventing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrically actuated valves with solenoids are used, then the valve structure is compact and controllable, but the flow factor is limited (0.8-1.2 Kv) and debris tolerance is low (1.8 mm or less)
Solution Approach 1:
The patent applies pneumatic actuation using compressed air to drive a piston mechanism that opens the valve. This hydraulic/pneumatic system enables a larger valve opening and greater flow factor (Kv > 1.5) compared to solenoid actuation, while the piston design provides high debris tolerance by maintaining reliable sealing even with particulates present in the coolant system
Solution Approach 2:
The patent changes the actuation mechanism from electrical (solenoid) to pneumatic (compressed air piston), fundamentally altering the operational parameters. This enables larger valve aperture and opening distance, achieving flow factor greater than 1.5 Kv and debris tolerance exceeding 1.8 mm while maintaining compact valve housing dimensions
2Loss of time
If the valve allows coolant flow to heat DEF, then the DEF thaw time is reduced, but the valve may leak when closed causing overheating of DEF
Solution Approach 1:
The patent extracts the sealing function from the valve closure mechanism by using a dedicated biasing element (spring) that actively pushes the valve closed. This separate sealing mechanism ensures the valve achieves complete closure with reliable sealing contact, preventing coolant leakage that would cause DEF overheating, while the pneumatic actuation enables sufficient opening for rapid thawing
3Productivity
If the valve is designed for high flow factor, then the system flow rate increases and thaw time reduces, but the valve complexity increases
Solution Approach 1:
The patent nests the piston actuator mechanism within the valve body housing. The compressed air piston, biasing spring, and valve closure mechanism are integrated into a compact nested arrangement where the piston moves within the valve housing to directly actuate the closure element. This nested design achieves high flow factor (Kv > 1.5) through large valve opening while maintaining compact overall valve dimensions and avoiding excessive structural complexity
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 fluid actuated valve achieves higher system flow rates, reduced thaw time for DEF, and increased debris tolerance, preventing emissions-related failures and overheating, while maintaining compactness and insulating heat energy effectively.
Implementation Method 1
a valve; and an actuator configured to actuate the valve, wherein the actuator comprises a fluid actuated piston; and wherein the valve is normally closed valve and biased by a biasing element to a valve closed condition
Implementation Method 2
an actuator configured to actuate the valve, wherein the actuator comprises a fluid actuated piston
Implementation Method 3
an inlet port configured for fluid communication with one of a coolant source or a heat exchanger of a DEF tank; an outlet port configured for fluid communication with the other of the heat exchanger of a DEF tank or the coolant source
Data Source
AI summary
A fluid actuated normally closed coolant control valve. The valve comprises a valve housing, an inlet port, the inlet port configured for fluid communication with either a coolant source or a heat exchanger of a DEF tank; an outlet port configured for fluid communication with the other of the heat exchanger of a DEF tank or the coolant source; a valve chamber, a valve and an actuator configured to actuate the valve. The actuator is a fluid actuated piston. The valve is biased to a closed condition in which the flow of coolant from the inlet port to the outlet port is prevented by the valve. The valve is actuatable to an open condition in which the flow of coolant from the inlet port to the outlet port is permitted, and the valve is withdrawn from the valve chamber, wherein the flow factor for the valve is greater than 1.5.