Cooler Bypass Manifold Plugging for Reliable ATF Cooling
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Solution Overview
Problem
Existing cooler bypass manifolds in automatic transmissions face challenges in maintaining optimal automatic transmission fluid (ATF) temperatures, leading to potential transmission failures due to viscous ATF at low temperatures or overheating at high temperatures, and existing modifications are inconsistent, time-consuming, and costly.
Innovation Solution
A modified cooler bypass manifold with a plug installed in the thermal valve bore and an OE pressure bypass valve assembly, allowing for direct ATF flow to the cooler or back to the transmission case based on fluid pressure, ensuring consistent and reproducible temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermal bypass valve assembly is removed or blocked to ensure continuous ATF flow to the cooler, then ATF temperature control reliability is improved, but the device complexity increases due to required modifications
Solution Approach 1:
The patent removes the thermal bypass valve assembly from the cooler bypass manifold, extracting the problematic component that causes inconsistent ATF temperature control. This extraction eliminates the failure mode where the valve incorrectly directs ATF away from the cooler, thereby improving temperature control reliability without requiring complex replacement mechanisms
Solution Approach 2:
Instead of using a thermal valve to bypass the cooler when hot, the patent inverts the approach by creating a pressure-actuated system that forces ATF through the cooler when hot. The inversion transforms the control logic from thermal-based bypass to pressure-based cooling enforcement, improving reliability while maintaining simplicity
2Reliability
If technicians perform custom modifications to block or remove the thermal bypass valve assembly, then ATF temperature control is improved, but the ease of manufacture deteriorates due to inconsistent and time-consuming modification processes
Solution Approach 1:
The patent incorporates the plug feature directly into the cooler bypass manifold during original equipment manufacturing, performing the modification action beforehand. This preliminary action eliminates the need for post-manufacturing technician interventions, ensuring consistent results across all units while maintaining ease of manufacture through standard production processes
Solution Approach 2:
The patent creates a standardized modified design that can be replicated across multiple units through normal manufacturing processes. By establishing a proven modification approach (the plug feature) and incorporating it into the original design, the patent enables consistent reproduction of the temperature control solution without requiring individual technician expertise or custom fabrication for each unit
3Adaptability or versatility
If a non-OE pressure bypass valve assembly is installed to allow continued operation during cooler restriction, then adaptability is improved, but the ease of operation deteriorates due to loss of thermal bypass functionality
Solution Approach 1:
The patent combines the cooling enforcement function with the existing pressure bypass valve assembly, creating a multi-functional system. The pressure bypass valve serves dual purposes: it continues to protect against pressure buildup and now also enforces ATF flow through the cooler when hot, eliminating the need for separate thermal bypass functionality while maintaining adaptability to cooler restrictions
Solution Approach 2:
The patent merges the thermal management function with the pressure bypass function into a single integrated system. By combining these functions, the patent simplifies the overall system operation while maintaining the ability to handle cooler restrictions, improving ease of operation by reducing the number of separate control mechanisms required
4Ease of operation
If the thermal bypass valve assembly is retained in the OE cooler bypass manifold, then ease of operation is maintained, but the reliability deteriorates due to potential valve failure directing ATF away from the cooler
Solution Approach 1:
The patent removes the thermal bypass valve assembly from the system, extracting the unreliable component that fails to properly direct ATF flow. This extraction eliminates the failure mode where the valve incorrectly bypasses the cooler, thereby improving reliability while the plug feature ensures ATF is forced through the cooler when needed
Solution Approach 2:
The patent introduces a plug feature as an intermediary element in the cooler bypass manifold. This plug acts as a mediator that physically blocks the bypass path, ensuring ATF flows through the cooler when hot without requiring a thermal valve to make active control decisions, thereby improving reliability while maintaining automatic operation
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 modified manifold provides effective and reproducible ATF temperature control, preventing transmission failures by ensuring continuous ATF flow to the cooler during normal operation, maintaining suitable temperatures and reducing the need for complex and costly modifications.
Implementation Method 1
a plug (430) configured for installation in the thermal valve bore (120)
Implementation Method 2
an OE pressure bypass valve assembly (150) disposed in the pressure valve bore (122)... allowing for direct ATF flow to the cooler or back to the transmission case based on fluid pressure
Implementation Method 3
directing ATF to the cooler to remove heat and avoid unsuitably high ATF temperatures
Data Source
AI summary
A modified cooler bypass manifold includes a manifold body having an inlet conduit, an outlet conduit, a return conduit, a thermal valve bore, a pressure valve bore and an intermediate conduit. A plug may be installed in the thermal valve bore. In another embodiment, a modified cooler bypass manifold includes an OE manifold body, a first inlet conduit, a second inlet conduit, a first outlet conduit, a second outlet conduit and a valve bore. The modified cooler bypass manifold may also include a pressure bypass valve assembly disposed in the valve bore. An OE end cap and retaining ring may be disposed in the valve bore and operably connected to the pressure bypass valve assembly and the OE manifold body.