Engine Cover Plate Coolant Cavity Design

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Solution Overview

Problem

Conventional coolant circuit designs in internal combustion engines suffer from flow control losses due to abrupt changes in coolant flow direction, which can lead to inefficiencies in heat exchange and increased component complexity.

Innovation Solution

A coolant cavity configuration and cover plate design that directs coolant flow from the water pump outlet to the water jacket inlet down a slope, reducing flow control losses and integrating engine oil and coolant circuits for improved heat management, while minimizing the number of engine block components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If coolant flow direction changes abruptly in conventional coolant cavities, then coolant can be directed from pump outlet to water jacket inlet, but flow control losses increase

Engineering Contradiction:

Improvecoolant flow direction controlVSAvoidflow control losses

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The coolant cavity incorporates curved surfaces and smooth transitions instead of abrupt angular changes. The cavity is shaped to guide coolant flow along a curved path from the pump outlet to the water jacket inlet, eliminating sharp direction changes and reducing flow control losses while maintaining effective coolant distribution.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Device complexity

If the number of engine block components is reduced by integrating oil and coolant circuits, then component complexity decreases, but heat absorption between circuits increases

Engineering Contradiction:

Improvenumber of engine block componentsVSAvoidundesired heat absorption

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The engine block is divided into distinct coolant cavities and oil passages that are spatially separated. The coolant cavity is positioned and shaped to maintain adequate distance from oil injection points and oil passages, creating thermal zones that prevent unwanted heat transfer from hot oil to the coolant circuit while still allowing component integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the engine block are designed with different thermal characteristics. Areas where oil and coolant circuits are in proximity incorporate thermal insulation or increased spacing, while other regions allow closer integration. The cover plate and cavity positioning create local thermal management zones that prevent harmful heat absorption in critical areas.

Inventive Principle:

Principle #3Local quality

3Device complexity

If coolant cavity is positioned close to oil injection points, then component integration increases, but heat transfer from oil to coolant increases

Engineering Contradiction:

Improvecomponent integrationVSAvoidheat transfer from oil to coolant

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The coolant cavity and oil passages are nested within the engine block structure at different depth levels and spatial positions. The cover plate seals the coolant cavity while oil passages are routed through different planes of the block, allowing compact integration without direct thermal contact between the two fluid circuits.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 design enhances fluid flow control, reduces undesired heat absorption, and allows for more effective cooling by reducing the number of engine block components and integrating oil and coolant circuits, thereby improving engine efficiency and fuel economy.

Implementation Method 1

directs the flow of coolant from the water pump outlet port to the water jacket inlet port down a slope, thus decreasing flow control losses

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

Liquid coolant absorbs excess heat from combustion and transfers the heat into the air or cabin of the vehicle via respective heat exchangers

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 3

heat is exchanged via conductive metal passageways surrounding the combustion chambers

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 4

oil is accelerated by an oil pump coupled to an oil injector within the engine block. This oil injector deposits oil on the underside of the piston where heat is absorbed and then deposited via a heat exchanger

Methodology Applied

Scientific EffectHeat absorption: Absorption (physical)

Implementation Method 5

the proximity of the engine oil and coolant is reduced and undesired heat absorption into the cooling system reduced to provide more effective cooling

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10190480B2Engine cover plate

Publication Date: 2019.01.29 FORD GLOBAL TECH LLC

AI summary

A engine block cover plate is described having a depression shaped to guide coolant flow around a bend in a coolant circuit, the plate further including a plurality of oil ports. One example method of operation may include guiding a coolant flow around a bend in a cooling circuit within an engine block via the cover plate, the cover plate having coolant and oil ports positioned therein, and adjusting a valve positioned on the cover plate to control a flow of oil through the oil port in response to an engine component temperature. In this way, flow losses may be decreased while enabling improved oil flow control with reduced system complexity.