Internal Combustion Engine Cooling System Valve Configuration
Solution Overview
Problem
The existing cooling systems for internal combustion engines require multiple valves to control the flow of cooling medium to the radiator, heater core, and EGR cooler, leading to increased costs and potential overheating issues if a valve malfunctions, especially in cold conditions where defrosting is necessary.
Innovation Solution
A cooling system with a simplified on-off valve configuration that can open and close using electromagnetic solenoids, allowing the cooling medium to bypass a malfunctioning flow control valve and ensure heat radiation to the heater core, eliminating the need for exclusive valves and reducing system costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple valves are provided to control cooling medium flow to radiator, heater core, and EGR cooler separately, then flow control precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple valve functions into a single on-off valve located at the engine outlet. This single valve controls the total flow of cooling medium leaving the engine, replacing what would traditionally require multiple separate valves for the radiator, heater core, and EGR cooler circuits. The merging reduces component count and system complexity while maintaining effective flow control through centralized management.
Solution Approach 2:
The single on-off valve performs a universal function of controlling cooling medium flow to multiple destinations (radiator, heater core, EGR cooler) simultaneously. By positioning the valve at the common outlet of the engine water jacket, it regulates flow distribution to all downstream components without requiring dedicated control valves for each circuit, thus achieving multi-functionality with a single component.
2Reliability
If multiple valves are provided for separate flow control, then reliability against overheating is improved, but system cost increases
Solution Approach 1:
The patent merges multiple valve functions into a single on-off valve at the engine outlet, reducing the number of potential failure points. Instead of having multiple valves that could each malfunction and cause overheating, the system uses one reliable valve to control total flow, combined with a bypass mechanism that ensures continuous cooling capability even if the main valve fails.
Solution Approach 2:
The system incorporates a bypass passage that provides a backup cooling path before a valve malfunction can cause overheating. The bypass is designed to automatically allow cooling medium flow if the main on-off valve fails to open, providing beforehand cushioning against the harmful effect of valve failure. This ensures reliability without requiring multiple expensive valves.
3Device complexity
If a single on-off valve is used instead of multiple valves, then device complexity is reduced, but flow control flexibility is worsened
Solution Approach 1:
The patent segments the cooling system into two functional paths: a main controlled path through the on-off valve to the radiator and heat exchangers, and a bypass path that operates independently. This segmentation allows the single valve to control the primary cooling flow while the bypass provides automatic flow division, effectively creating flexible flow control without requiring multiple valves. The bypass can be activated or deactivated based on system conditions, providing adaptability.
Solution Approach 2:
The bypass passage acts as an intermediary element that mediates between the single on-off valve and the multiple cooling destinations. When the main valve is closed or restricted, the bypass provides an alternative route for cooling medium to reach the radiator and other components, effectively translating the single valve's binary control into flexible multi-path flow management.
4Ease of manufacture
If the valve is positioned at the engine outlet, then ease of manufacture is improved, but cooling coverage is worsened
Solution Approach 1:
The patent segments the cooling flow into a main controlled stream through the on-off valve at the engine outlet and a bypass stream that can be activated independently. This segmentation ensures that even though the valve is positioned at the outlet (easy to manufacture and install), the bypass mechanism provides direct cooling coverage to critical components, maintaining reliable cooling coverage despite the simplified valve placement.
Solution Approach 2:
The bypass passage is designed as a beforehand cushioning measure to ensure cooling coverage even if the outlet-positioned valve fails to open properly. The bypass provides a pre-established alternative path that guarantees cooling medium reaches the radiator and heat exchangers, compensating for the potential limitation of having the valve at the engine outlet rather than at each individual component.
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 system effectively prevents overheating by ensuring continuous heat radiation to the heater core even if the flow control valve fails, while reducing system costs by minimizing the number of valves required and maintaining efficient defrosting functionality.
Implementation Method 1
a solenoid suctioning the valve body by an electromagnetic force so that the valve body makes contact with the valve seat
Implementation Method 2
a cooling system supplying a cooling medium of an internal combustion engine to a radiator and a heat exchanging portion which is different from the radiator
Implementation Method 3
a flow passage for sending out coolant of an engine to a radiator
Implementation Method 4
ensuring continuous heat radiation to the heater core
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
To construct a cooling system at a reduced cost which may restrain overheat of an internal combustion engine even in a case where a valve for controlling a cooling medium is broken down. A first flow passage supplying the cooling medium of the internal combustion engine to a radiator and a second flow passage branching from the first flow passage by a flow control valve to supply the cooling medium to a first heat exchanging portion are provided. In addition, a third flow passage provided separately from the first flow passage to supply the cooling medium to a second heat exchanging portion via an on-off valve is provided. A control apparatus controlling the on-off valve and the flow control valve based on a temperature of the cooling medium is provided.