Integrated Coolant Valve with Wax Driver
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Solution Overview
Problem
Current engine systems with single coolant control valve units face issues with increased weight, part count, production, and maintenance costs due to the need for separate bypass lines and valves to prevent coolant overheating, which also lead to inefficiencies in engine performance and passenger comfort.
Innovation Solution
An engine system with a coolant control valve unit that uses a temperature-sensitive driver, such as a wax-filled casing, to actively control the opening of valve members via a motor and controller, eliminating the need for separate safety or bypass valves by adjusting coolant passage openings based on temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bypass lines and bypass valves are installed to prevent coolant overheating, then coolant temperature control reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the bypass valve function with the main coolant control valve unit into a single integrated structure. The bypass valve is positioned adjacent to the main valve body and shares common mounting features, eliminating the need for separate bypass lines and reducing overall system complexity while maintaining the ability to independently control both main and bypass coolant flows for reliable temperature management
Solution Approach 2:
The coolant control valve unit is designed with multi-functionality, where a single valve assembly performs both the primary coolant flow control and the bypass flow control functions. This universal design allows one valve unit to handle multiple temperature control scenarios without requiring separate dedicated valves for each function
2Reliability
If separate bypass lines and bypass valves are installed to prevent coolant overheating, then coolant temperature control reliability is improved, but weight increases
Solution Approach 1:
The bypass valve is integrated into the main valve body structure, sharing common materials, mounting features, and housing. This merging eliminates redundant components and reduces the total weight compared to having completely separate bypass valve assemblies and dedicated bypass piping
3Reliability
If separate bypass lines and bypass valves are installed to prevent coolant overheating, then coolant temperature control reliability is improved, but production cost and maintenance cost increase
Solution Approach 1:
The integrated valve design allows both the main coolant control valve and bypass valve to be manufactured as a single assembled unit or even as an integrated component. This reduces the number of separate manufacturing processes, inventory items, and assembly steps required, thereby lowering production costs while maintaining reliable temperature control through dual-valve functionality
4Device complexity
If one coolant control valve unit is used to control coolant temperature, then device complexity is reduced, but the valve may become fixed and improperly operated leading to coolant overheating
Solution Approach 1:
The patent employs two independently controllable valves (main coolant control valve and bypass valve) that can dynamically adjust coolant flow based on operating conditions. This dynamic control capability allows the system to adapt to varying temperature requirements and prevent overheating, while the electronic control system manages the complexity of coordinating both valves
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 improves coolant control stability at high temperatures, reduces system complexity and weight, and enhances engine performance by dynamically managing coolant flow without additional valves, thus lowering production and maintenance costs.
Implementation Method 1
the wax may shrink and expand depending on a coolant temperature to push the piston rod to a side of the cam member or to pull the piston rod reversely
Data Source
AI summary
An engine system having a coolant control valve unit includes: first and second valve members each having a rod protruding through a center part of the first and second valve members, respectively; a third valve member having a piston rod disposed through a center part of the third valve member; a temperature-sensitive driver attached to one side surface of the third valve member; a cam member contacted with an end part of the first and second rods and of the piston rod; and a cam member driver to rotate the cam member and control an opening of first, second, and third coolant passages by the first, second and third valve members, respectively. In particular, the other end part of the piston rod is inserted into the temperature-sensitive driver to push or pull the piston rod depending on a sensed temperature of the coolant.