Glow Plug Electric Thermostat Rapid Heat Control

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Solution Overview

Problem

Existing vehicle thermostats, particularly mechanical ones, struggle to rapidly adjust coolant temperatures in response to changing driving conditions, leading to inefficiencies in fuel consumption and exhaust emissions due to slow heating times of electric thermostats.

Innovation Solution

A glow plug-based electric thermostat design that includes a hollow plug housing, a center shaft, a heating unit, and a connecting unit with integral terminal couplers, allowing for rapid heat generation and insulation, enabling real-time coolant temperature control and improved fuel efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a film resistance type heater is used in an electric thermostat, then the thermostat can control coolant temperature, but it takes 50-70 seconds to reach the desired temperature of 300-350°C

Engineering Contradiction:

Improveheating temperatureVSAvoidtime to reach desired temperature

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent replaces the film resistance type heater with a glow plug heater, which is originally designed for rapid heating in internal combustion engines. The glow plug's heating element, when supplied with 12V power, generates heat much more quickly than film resistance heaters, reducing the time to reach 300-350°C from 50-70 seconds to approximately 10 seconds. This substitution of heating technology directly resolves the time-loss contradiction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the electrical parameters of the heating system by using a glow plug designed for 12V automotive electrical systems rather than the lower voltage typically used with film resistance heaters. This higher voltage enables much faster heating by increasing the power delivery (P=V²/R), allowing the heating element to reach the required 300-350°C temperature range in significantly less time, thus resolving the time-to-temperature contradiction.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If a mechanical thermostat is used, then the structure is simple, but it cannot actively respond to changing driving conditions and maintains coolant flow only at predetermined temperatures

Engineering Contradiction:

Improvethermostat structureVSAvoidresponse to driving conditions

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the purely mechanical thermostat system with an electrically controlled system using a glow plug heater and temperature sensor. This electrical system can be controlled by the vehicle's ECU to actively adjust coolant temperature based on driving conditions, engine load, and ambient temperature, providing adaptability that mechanical thermostats cannot achieve while maintaining relatively simple implementation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transforms the static, predetermined temperature control of mechanical thermostats into a dynamic control system. The glow plug-based electric thermostat can continuously adjust its heating output in response to changing driving conditions, engine operating parameters, and coolant temperature feedback, enabling real-time adaptation rather than fixed threshold operation.

Inventive Principle:

Principle #15Dynamics

3Productivity

If the heating element takes long to reach desired temperature, then fuel efficiency decreases, but using a faster heating system increases control responsiveness

Engineering Contradiction:

Improvecontrol responsivenessVSAvoidfuel efficiency

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent substitutes the slow film resistance heater with a glow plug heater that reaches operating temperature in approximately 10 seconds compared to 50-70 seconds for film heaters. This rapid heating capability allows the thermostat to respond quickly to control signals, improving control responsiveness and enabling more efficient engine warm-up, which directly improves fuel efficiency by reducing the time the engine operates suboptimally.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 glow plug system minimizes the time to reach desired temperatures, enhancing control responsiveness and maximizing fuel efficiency by allowing the electric thermostat to quickly adjust coolant temperatures in response to driving conditions.

Implementation Method 1

a heating unit that is connected to the center shaft and the other end of the plug housing, and generates heat using a potential difference

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a connecting unit that insulates the plug mount and the center shaft

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9062592B2Glow plug and electric thermostat with the same

Publication Date: 2015.06.23 HYUNDAI MOTOR CO LTD

AI summary

A glow plug may include: i) a hollow plug housing that is mounted on a plug mount in an insulation status; ii) a center shaft that is fixed to one end of the plug housing in an insulation status and receives power from the outside; iii) a heating unit that is connected to the center shaft and the other end of the plug housing, and generates heat using a potential difference; and iv) a connecting unit that insulates the plug mount and the center shaft, is coupled to the plug mount, and electrically connects with center shaft with the plug housing.