Fuel Pump Controller Integrated Air Filter Heat Dissipation

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Solution Overview

Problem

Conventional fuel pump controllers in vehicles lack an effective cooling mechanism, leading to reduced durability and poor purge efficiency due to heat generation, and the separate air filter configuration increases production costs and complexity.

Innovation Solution

A fuel pump controller with an integrated air filter that allows for heat dissipation from the motor driver's circuit board, enhancing purge efficiency by using the air filter for heat exchange and reducing the number of components and production costs through a modular design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the fuel pump controller is provided separately from the air filter, then the controller can be easily installed and maintained, but the controller generates excessive heat and lacks cooling mechanism reducing its durability

Engineering Contradiction:

Improvecontroller durabilityVSAvoidcontroller heat generation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent combines the air filter and fuel pump controller into a single integrated assembly. The controller is mounted directly on the air filter housing, allowing the air filter structure to serve as the controller mounting structure. This integration enables the controller to benefit from the air filter's natural airflow for cooling while reducing the need for separate cooling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The air filter housing serves multiple functions: it filters air for the engine and simultaneously acts as a heat sink and mounting structure for the fuel pump controller. The airflow path designed for cooling the air filter also cools the controller, eliminating the need for dedicated cooling components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If the air filter is integrated with the fuel pump controller, then production costs and device complexity are reduced, but the heat dissipation efficiency may be compromised

Engineering Contradiction:

Improvenumber of componentsVSAvoidheat dissipation efficiency

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The air filter and fuel pump controller are merged into a single integrated assembly where the controller is mounted on the air filter housing. This reduction in component count simplifies the overall system while maintaining effective heat dissipation through the housing's airflow path.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated design allows the air filter's natural airflow to automatically cool the controller without requiring additional cooling components or complex thermal management systems. The structure serves its own cooling needs through its operational airflow.

Inventive Principle:

Principle #25Self-service

3Productivity

If the controller continuously consumes power for operation, then it can maintain engine operation control, but it generates continuous heat that deteriorates its durability

Engineering Contradiction:

Improveengine control continuityVSAvoidheat generation from continuous operation

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The controller utilizes the airflow naturally present in the air filter system to cool itself during continuous operation. The breathing airflow of the air filter serves as a passive cooling mechanism, allowing the controller to maintain continuous operation without additional active cooling components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The heat generated by the continuously operating controller is dissipated through the air filter's airflow path. The same airflow necessary for engine operation also serves to remove heat from the controller, converting a potential problem (heat generation) into a beneficial cooling effect.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 integrated air filter module efficiently recycles heat, improving both controller cooling and purge efficiency, while reducing production costs and maintaining the air filter's functionality, thus addressing the issues of heat management and purge efficiency.

Implementation Method 1

an air filter having a filter element to remove a foreign substance from air

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

the filter case is integrally disposed on the mounting plate to enable heat exchange between the air passing therethrough and the motor driver

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS10330056B2Fuel pump controller integrated with air filter

Publication Date: 2019.06.25 HYUNDAI MOTOR CO LTD

AI summary

A fuel pump controller having an integrated air filter includes: a mounting plate fixed to a fuel tank; a motor driver provided on the mounting plate; an air filter having a filter sheet disposed inside a filter case to remove a foreign substance from air and having an air inlet port for air introduction; and an air outlet port for discharging the air, which has passed through the filter sheet. The filter case is integrally disposed on the mounting plate to enable heat exchange between the air passing therethrough and the motor driver.