Expansion Compensating Seal for Electric Coolant Pump Thermal Cycling
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Solution Overview
Problem
Electric coolant pumps face challenges in maintaining a watertight seal due to thermal cycling, which causes components to expand and contract at different rates, leading to undesirable gaps and reduced lifespan.
Innovation Solution
The electric coolant pump system incorporates an expansion compensating seal between the end cap and the main body of the housing, utilizing a compressible material to maintain a seal despite thermal expansion and contraction of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rigid seals are used in electric coolant pumps, then the seal structure is simple and manufacturing is easy, but the seal fails to compensate for thermal expansion/contraction of components, leading to gaps and leakage
Solution Approach 1:
The seal transitions from a rigid state to a compliant state by changing its material properties. The seal is designed to deform elastically in response to thermal expansion and contraction of the pump housing, maintaining continuous contact with sealing surfaces. This parameter change allows the seal to adapt to dimensional changes in the housing without requiring complex adjustment mechanisms.
Solution Approach 2:
The seal utilizes a flexible, compliant material that can deform to accommodate thermal cycling of the pump housing. This flexible seal element maintains sealing pressure against the housing bore and end cap surfaces despite changes in housing dimensions, preventing coolant leakage while keeping the overall seal structure relatively simple.
2Reliability
If rigid sealing surfaces are used between housing components, then manufacturing precision can be maintained, but thermal cycling causes components to expand/contract at different rates, creating gaps and compromising the seal
Solution Approach 1:
The seal material's physical parameters (elasticity, compliance) are selected to match the thermal expansion characteristics of the housing materials. This allows the seal to compensate for differential thermal expansion between the housing, end cap, and seal itself, maintaining sealing effectiveness across the full thermal operating range of the coolant pump.
Solution Approach 2:
The compliant seal acts as an intermediary element between the housing components, absorbing dimensional changes and preventing direct contact between rigid sealing surfaces that would otherwise create gaps. This intermediary seal maintains continuous sealing pressure despite thermal cycling of the surrounding structure.
3Ease of repair
If the housing is designed to be serviceable with removable covers, then ease of repair is improved, but maintaining a reliable seal across the service interface becomes more difficult due to thermal expansion variations
Solution Approach 1:
The seal's flexibility allows it to accommodate the slight misalignments and dimensional changes that occur at service interfaces where covers are removed and reinstalled. This compliant seal maintains sealing effectiveness even when the housing undergoes thermal cycling after service, preventing leakage at the service interface.
Solution Approach 2:
The seal is designed with dynamic compliance that allows it to adapt to changing dimensional relationships between housing components during thermal cycling. This dynamic adjustment capability ensures the seal remains effective whether the pump is in service or has recently undergone maintenance, bridging the gap between serviceability and seal reliability.
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 maintains a watertight seal throughout the engine's thermal range, enhancing durability, serviceability, and longevity while being cost-effective and easy to manufacture.
Implementation Method 1
One or more components of the electric coolant pump system thermally expand and contract as the coolant is heated and cooled
Implementation Method 2
utilizing a compressible material to maintain a seal despite thermal expansion and contraction of components
Data Source
AI summary
An electric coolant pump system is presented including a housing having a main body and an end cap. The main body having a hollow interior and an open end. The end cap is operably connected to the main body and closes the open end of the main body. The system includes a rotor shaft operably connected to the housing. The system includes a rotor operably connected to the rotor shaft and positioned within the hollow interior. The system includes an impeller operably connected to the rotor. The system includes a stator configured to generate a rotating electromagnetic field during operation. The rotor is configured to rotate the impeller in response to the rotating electromagnetic field. The impeller is configured to pump a coolant when rotated. One or more components of the electric coolant pump system thermally expand and contract as the coolant is heated and cooled.